HYDRAULIC EXPERIMENTS

Experiment 01
Characteristic Curve of Variable Displacement Hydraulic Pump

Aim: To study hydraulic pump, its characteristics and calculate the hydraulic power

Definition

In a hydraulic system, fluid flow generators/hydraulic pumps convert the mechanical energy of a
drive motor (torque, speed) into hydraulic power (flow, pressure).
Hydraulic pumps are displacer pumps, the displacement of which can be either fixed or variable.
Hydraulic pumps that feature an adjustable displacement are called variable displacement pumps.
The displacement/flow is adjusted by means of mechanical or electronic control systems.
This experiment is to help the student to understand the following:
• With hydraulic variable displacement pumps, the flow is almost reduced to zero when
the system pressure has been reached.
• Due to the design of a variable displacement pump, internal leakage oil occurs, which is
re-fed to the reservoir through an external leakage oil line.
• The leakage oil flow increases as the resistance rises, which opposes the displacement
in the pressure line of the pump
• The drained leakage oil flow is the power loss of the hydraulic pump.
With the help of the control set up on the training system, the student can recognize that when
the system pressure increases as resistance at the pressure port of the hydraulic pump, the total
displacement reduces. The resistance is realized by means of a hand lever valve, with the system
pressure being sleeplessly variable via a pressure relief valve operated in parallel.
 Table 1.1: Component Selection with parts list

Note: The pilot operated, variable vane pump is not included as individual component in parts list
in table 1.1 It is an integral part of the hydraulic power unit.
Circuit Diagram Hydraulic pump/characteristic curve of variable displacement pump
 Execution of the experiment
Set-up of the control as described in the following:

1. Mount the components required according to Table 1.1 on the training system in a clearly
arranged manner according the prepared circuit diagram. Connect the hydraulic control
according to hydraulic circuit diagram Fig. 1.1 by means of hoses. For connections, to which
pressure gauges with minimess hose DZ 1.4 are to be connected, use hydraulic hoses DZ25.1
Hand-tighten the pressure gauge measuring lines hand tight at the relevant minimess
connection of the hydraulic hose. The proper and tight fit of hose connections of components
can be easily checked by slightly turning the hoses.
Before commissioning the hydraulic control, i.e. before switching the hydraulic pump on,
check, whether all pressure control valves are set to minimum pressure (spring unloaded) and
all throttle valves are open.
Completely close throttle valve item 1.1. To this end, turn the adjustment element clockwise
to the mechanical limit stop. Close shut-off valve item 1.2.
2. Switch the hydraulic pump on, check and set up control for any leakage.
3. Adjust the system pressure on pressure relief valve item 1.0 to 50 bar plus one turn.
4. Check the set pressure on the variable displacement pump of the drive power unit (zero
stroke pressure 50 bar).
5. Open shut-off valve item 1.2.

6. Open throttle valve item 1.1 until a pressure of 15 bar is present at measuring point M1.

7. Measure the flow using the measuring glass; to this end, close shut-off valve item 1.2, close
the measuring glass, open shut-off valve item 1.2 for 1 liter. Record the filling quantity and
enter the measured value in Table 1.2
8. Take flow measurements as described in points 6 and 7, at pressure values of 25 bar, 30 bar,
40 bar, 45 bar and 50 bar and enter the recorded measured values in Table 1.2
9. After completion of practical work, switch the hydraulic pump on the training system off.
Turn pressure relief valve item 1.0 back to minimum pressure. Open throttle valve item 1.1
completely. None of the pressure gauges should indicate a pressure!
10. Calculate the measured oil flow/time and enter it as flow in qv = lts/min in table1.2.
 Table 1.2: Measurement oil volumes

Pressure Volume in mm³ Time in s Lt/min m³/min

P V t
1 lt
1 lt
1 lt

11. Enter the individual values as points and connect the individual points with a line to create a
curve. The resulting curve is the typical characteristic curve of the pilot operated, variable
vane pump.
12. Calculate the hydraulic power, P in kW
13. Evaluate the results

Characteristic Curve of the Hydraulic Pump

14. Conclusion
 Experiment 02

Pressure Intensification

Aim: To Study pressure intensification of a single-rod cylinder

Definition

If in a hydraulic system the hydraulic force, which is converted into mechanical energy, is to be
transmitted to an actuator in the form of a linear (straight) movement, a hydraulic cylinder is
used. The hydraulic cylinder as output element forms the link between the hydraulic circuit and
the working element/tool in a technological system. Lifting, lowering, locking and transporting
loads are typical applications of hydraulic cylinders.

The piston velocity v in m/s of the hydraulic cylinder is determined by the pump flow supplied.
Flow control valves are used to vary the piston velocity. In this project, the student is to work out
the physical basic principles of pressure intensification with single rod cylinders. On the basis of
this experiment, he/she is to understand the following:

• The hydraulic cylinder performs a straight movement and transmits the supplied piston
pressure in the form of force.
• Double-acting hydraulic cylinders with different piston areas are pressure intensifiers.
• Due to adhesive friction in the hydraulic cylinder the pressure actually transmitted via the
piston area or through the differences in areas is reduced.
• Forces and velocities can be kept constant over the entire stroke.

Based on the control set up on the training system the student is to learn that the use of a meter
out throttle on the piston rod side involves a risk of pressure intensification. When the hydraulic
pump is switched on, the piston of the single-rod cylinder extends. The extension velocity can be
varied by means of a throttle valve. Retracting of the single-rod cylinder is accomplished with
the help of a 4/2 directional valve.
Experiment definition
A work piece is to be shifted by a horizontally installed single-rod cylinder to the working range
of a simple fixture when the hydraulic pump is switched on. To this end, the extension velocity
of the cylinder must be adjustable. Retracting is to be achieved by means of a 4/2 directional
valve. The installed throttle valve on the piston rod side and, while adjusting the extension
velocity, recognizes that the pressure upstream of the throttle becomes higher than the set system
pressure.

Practical example: Hydraulic cylinder of tie rod design

Table 2.1: Component Selection with parts list
Single-rod cylinder/pressure intensification
Hydraulic Circuit Diagram

Fig 2.1
Electrical Circuit Diagram for Pressure Intensification
Execution of the order
1. Mount the components required according to Table 2.1 in a clearly arranged form on the
training system according to the prepared circuit diagram. Connect the hydraulic control
according to hydraulic circuit diagram Fig. 2.1 by means of hoses. For connections, to
which pressure gauges with minimess line DZ 1.4 are to be connected, use hydraulic hoses
DZ 25.1 Hand-tighten the pressure gauge measuring lines at the relevant minimess connection
of the hydraulic hose. The correct and proper fit of the component connections with hoses can
be checked by slightly turning the hoses.
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Check the pressure set on the variable displacement pump of the drive power unit (if
required, correct to 50 bar).
4. Set the system pressure on pressure relief valve Item 1.2 to 50 bar plus one turn; operate push-
button S2 to prevent the piston of hydraulic cylinder Item 1.0 from extending.
5. Through operation of push-button S1 the control voltage of solenoid Y1 of the 4/2 directional
valves Item 1.1 drops, and the piston of the hydraulic cylinder extends due to the pump flow
supplied directly to the piston side.
6. Switch the hydraulic pump off and wait until the system is depressurized. Close throttle
valve Item 1.3. To this end, turn in the adjustment element counter-clockwise to the limit stop.
7. Switch the hydraulic pump on. The piston of the hydraulic cylinder cannot extend, because
the counterforce on the piston rod side is greater than the force on the piston side, since the
throttle valve is closed. Pressure gauge M3 indicates the value of pressure intensification. Note
the measured values and enter them in Table 2.2.

Table 2.2

8. After having completed practical work on the training system switch the hydraulic pump off!
Turn pressure relief valve Item 1.2 back to minimum Caution pressure. No pressure gauge
may indicate a pressure!

9. Evaluate the results

.
Note: Calculation of pressure intensification on the basis of given hydraulic cylinder values.
Example:
 Experiment 03

Meter-in and Meter-out circuits

Aim: To study concepts of Meter-in and Meter-out circuits using Single-rod

cylinder and 4/2 DCV

Definition

If in a hydraulic system the hydraulic force, which is converted into mechanical energy, is to be
transmitted to an actuator in the form of a linear (straight) movement, a hydraulic cylinder is
used. The hydraulic cylinder as output element forms the link between the hydraulic circuit and
the working element/tool in a technological system. Lifting, lowering, locking and transporting
loads are typical applications of hydraulic cylinders.
The piston velocity v in m/s of the hydraulic cylinder is determined by the pump flow supplied.
Flow control valves are used to vary the piston velocity. In this experiment, the student is to
work out the physical basic principles of pressure intensification with single rod cylinders. On
the basis of this experiment, he/she is to understand the following:
• The hydraulic cylinder performs a straight movement and transmits the supplied piston
pressure in the form of force.
• Double-acting hydraulic cylinders with different piston areas are pressure intensifiers.
• Due to adhesive friction in the hydraulic cylinder the pressure actually transmitted via the
piston area or through the differences in areas is reduced.
• Forces and velocities can be kept constant over the entire stroke.

Based on the control set up on the training system the student is to learn that the use of a meter-
out throttle on the piston rod side involves a risk of pressure intensification. When the hydraulic
pump is switched on, the piston of the single-rod cylinder extends. The extension velocity can be
varied by means of a throttle valve. Retracting of the single-rod cylinder is accomplished with
the help of a 4/2 directional valve.
 Table 3.1: Component Selection with parts list

Item Qty Component Type Symbol

Designation Designation
Double acting
1.0 1 cylinder with single ZY1.3
sided piston rod
4/2 Directional valve
1.1 1 with solenoid DW3E
actuation with spring
return
Direct operated
1.2 01 pressure relief valve, DD1.1
the cracking
pressure can be
adjusted by means of
a spring
Throttle check valve,
1.3 01 adjustable, DF 2.2
free flow in one
direction

Distributor plate DZ 4.1

01 with four ports

Pressure gauge with DZ 1.4

0.1-0.3 03 hose and quick
release coupling
without check valve
Hose with quick DZ 25.1
03 release coupling
with check valve

Hose VSK1
 Meter-in-Circuit Task-1

Meter-out-Circuit

Meter-out circuit

Fig: 3.1
Meter-out circuits Task-2
Fig: 3.2
Electrical circuit diagram for Meter-in and Meter-out circuit

Fig 3.3
Execution of the experiment
1. Mount the components required according to Table 3.1 in a clearly arranged form on the
training system according to the prepared circuit diagram. Connect the hydraulic control
according to hydraulic circuit diagram Fig.3.1 by means of hoses. Wire the electrical control
according to wiring diagram Fig 3.3
2. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
3. Set the system pressure on pressure relief valve to 50 bars plus one turn.

Task 1: Meter-in throttle: Piston side extending

4. Adjust throttle check valve Item 1.3 so that the piston of the single-rod cylinder extends
within 5 s; to this end operate push-button S2. Enter the pressure values (during extending) on
piston side M2 and on piston rod side M3 in Table 3.4
Task 2: Meter-out throttle: Piston rod side extending
5. Convert the hydraulic control according to Hydraulic circuit diagram Fig. 3.2 Repeat
working steps 2 and 3.
6. Adjust throttle check valve Item 1.3 so that the piston of the single-rod cylinder extends within
5 s. To this end actuate push-button S2. Enter the pressure values (during extending) on piston
side M2 and on piston rod side M3 in Table 3.4

Table 3.4: Measurement results from the execution of the order

Measuring points —> M2 p in bar M3 p in bar

Meter-in throttle, piston side -
during extending
Meter-out throttle, piston
rod side -during extending
Meter-in throttle, piston side
«- during retracting
Extending Extending
Meter-out throttle, piston rod side
EEEEEEEEEextendin
«-
g during retracting

7. Evaluate the results

 Experiment 04

Center Configuration of 4/3 DCV

Aim: To study the application of different center configuration of 4/3 DCV

Definition: If the travel, direction, start, and stop of a hydraulic cylinder are to be controlled in a
hydraulic system, a directional valve must be used. Directional valves are differentiated as
follows: directional spool valves, direct operated, pilot operated and directional poppet valves.
Directional valves are elements that assume the task of opening, closing or changing the flow
paths in hydraulic systems.

With the help of the control set up on the training system the student gets familiar with the
possible application of a 4/3 directional valve. A hydraulic cylinder is to be controlled alternately
by a 4/3 directional valve with different spool shapes (blocked and circulation position). The
student can recognize the special features of different symbols by measuring the different
pressure differentials across the 4/3 directional valve. Internal leakage can be recognized by the
horizontal arrangement of the single-rod cylinder, on which no external forces act.
 With a valve is in the blocked position:
– A connected single-rod cylinder can extend due to internal leakage of the valve while the valve
is in its rest position and the pump is running.
– The total flow of a fixed displacement pump flows via the pressure relief valve to the tank
when the set system pressure is reached while the pump is running and the valve is in its rest
position, i.e. high power losses incur and the oil heats up.
– The working pressure utilized last slowly decreases via the clearance of the spool when the
hydraulic pump is switched off and the valve is in its rest position.
 With a valve is in the circulation position:
– When the valve is in its rest position and the pump is switched on the total pump flow flows
almost at zero pressure to the tank; the backpressure and hence the power loss is determined by
the pressure differential across the valve;
Energy is saved while the pump is running and the valve is in its rest position. This feature
cannot be installed in controls, where the system pressure is required by further actuators.
Experiment Definition
A single-rod cylinder is to shift and position tools horizontally in a fixture. When in the rest
position the hydraulic cylinder must not move, and the fixed displacement pump is to be spared
and thus energy saved. The customer wants to be informed about the pros and cons of the various
spool shapes, in particular blocked and circulation position. In order that the customer can
understand your proposed solution, he requires technical documentation such as the hydraulic
circuit diagram with parts list, and the required measured data for the spool shapes/symbols.
 Table 4.1: Component Selection with parts list

Item Qty Component Designation Type Designation Symbol

1 Double acting cylinder with
1.0 single sided piston rod ZY1.3
1 4/3 directional valve with direct
1.1 actuation by two solenoids, spring DW 4E
centering of the central position
and central position P - T, A, B

1 4/3 directional valve with direct

1.2 actuation by two solenoids, spring
centering of the central position DW 13E
and central position P, T, A, B

01 Direct operated pressure relief

1.3 valve, the cracking pressure can DD1.1
be adjusted by means of a spring
01 Throttle valve, adjustable DF 1.2
1.4

01 Distributor plate with four ports DZ 4.1

03 Pressure gauge with hose and DZ 1.4

01-0.3 quick release coupling without
check valve

03 Hose with quick release coupling DZ 25.1

with check valve

Hose VSK1
 4/3 DCV-Tandem Centre Task-1
DAC Single Rod Type; Dp=25mm; Dr=16mm; S=400mm

Fig 4.2
4/3 DCV-Closed Centre Task-2
Fig 4.3
Fig: Electrical circuit diagram for Tandem-Closed and Open

Fig 4.4
Execution of the experiment
Set up the control as described below:
1. Mount the components required according to Table 4.1 in a clearly arranged form on the
training system according to the prepared circuit diagram.
2. Connect the hydraulic control according to hydraulic circuit diagram Fig 4.2 by means of
hoses.
3. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge
may indicate a pressure.
4. Set the system pressure on pressure relief valve Item 1.3 to 30 bar. By actuating push-button
S3 solenoid Y1b of 4/3 directional valve Item 1.1 is energized. The pump flow is fed against
the piston rod side of hydraulic cylinder Item 1.0 and the system pressure can be set to 30
bar.
5. By actuating push-button S2 solenoid Y1a of 4/3 directional valve Item 1.1 is energized. The
piston of the hydraulic cylinder extends.
Measurements for task 1:
6. Measure the specified values in the end positions of the hydraulic cylinder and in the rest
position (central position) of the 4/3 directional valve as listed in Table 4.5 and enter the
values in Table 4.5
7. Modify the hydraulic control according to hydraulic circuit diagram 4.3 Proceed as
described in task one, steps 1 and 2.
Check the electrical control for correct wiring.
8. Switch the hydraulic pump on and inspect the set up control for leakage. No pressure gauge

may indicate a pressure.

9. Set the system pressure on pressure relief valve Item 1.3 to 30 bar.
10. By actuating push-button S3 solenoid Y1b of 4/3 directional valve Item 1.2 is energized. The
piston of hydraulic cylinder Item 1.1 extends. By actuating push-button S2 the piston of the
hydraulic cylinder retracts. In contrast to task 1, positions "a“and "b“of the 4/3 directional valve
are exchanged due to the spool shape/symbol.
Measurements for task 2:
10. Measure the specified values in the end positions of the hydraulic cylinder and in the rest

position (central position) of the 4/3 directional valve as listed in Table 4.6 and enter the values

in Table 4.6

Measured values for Task 1

Table 4.5

Measured values Task 2

Table 4.6

11. Evaluate the results

 PNEUMATICS EXPERIMENTS
Exercise 01 - Direct control of Double Acting Cylinder
Aim: The piston of a double acting cylinder should advance on actuation of a push button valve.
After releasing the push button the cylinder retract back to its initial position. It is required that
force should be exerted both during forward and return motion

Position of equipment on the working plate

Pneumatic circuit diagram

Table: List of Equipment

04 Double-acting Cylinder (Z1)

08 5/2 Way Directional Control Valve (Single Pivoted)
02 Distributor manifold ( 6 fold)
01 Air Service unit (Filter Regulator assembly)
Pneumatic circuit diagram

Fig. 01: Pneumatic Circuit diagram: Direct control of double acting cylinder

Selection: A Double acting cylinder has to be selected to meet the condition.

A single piloted valve can satisfy the task.

Task: The piston rod of a double-working cylinder (Z1) should extend after actuating a button.
After releasing the button (S1), the piston of the cylinder should retract automatically to
its back position. Additions to the circuit diagram. All connections should be marked
with the connection symbols according to ISO 5599.

Pneumatic circuit diagram

The cylinder is retracted in neutral position. The double-acting cylinder is directly controlled by
a manually operated 5/2 directional control valve. The spring cushioning mounted in the cylinder
can be adjusted.
 Exercise 02 - Indirect control of Double Acting Cylinder
Aim: indirect control of a double-acting cylinder with a pneumatically operated 5/2 directional
control valve.

Suggestion for the positioning of equipment on the working plate

Condition: It is required that force should be exerted only in during the forward motion
Table: List of Equipment

04 Double-acting Cylinder (Z1)

10 5/2 Way Directional Control Valve (Single Piloted)
06 3/2 way Push button valve (NC)
02 Distributor manifold ( 6 fold)
01 Air Service unit (Filter Regulator assembly)

Pneumatic circuit diagram

Fig. 01: Pneumatic Circuit diagram: Indirect control of double acting cylinder

Selection: A Double acting cylinder has to be selected to meet the condition. A single piloted
valve can satisfy the task.
Task: The piston rod of a double-acting cylinder (drive element Z1), retracted in neutral
 position, should extend after actuating a button (controlling element S1). Control of the
cylinder (Z1) should occur indirectly. After releasing the push-button (S1), the piston of
the cylinder should retract automatically to its back position. Additions to the circuit plan.
All connections should be marked with the connection symbols according to ISO 5599.

Pneumatic circuit diagram

A pneumatically operated 5/2 directional control valve (actuator) is controlled with a manually
operated 3/2 directional control valve (signaling element S1). The piston rod of the double-acting
cylinder (actuating drive Z1) extends.
 Indirect control of Single Acting Cylinder
Aim: Indirect control of cylinder, using a single-acting cylinder and a pneumatically operated
3/2 directional control valve.

Suggestion for the positioning of equipment on the working plate

Table: List of Equipment

03 Single -acting Cylinder (Z1)

09 3/2 Way Directional Control Valve (Single Piloted) [Use 5/2 way Single piloted
valve and block port B]

06 3/2 way Push button valve (NC)

02 Distributor manifold ( 6 fold)

01 Air Service unit (Filter Regulator assembly)

Pneumatic circuit diagram

 Fig. 01: Pneumatic Circuit diagram: Indirect control of single acting cylinder

Task: The piston rod of a single-acting cylinder (Z1), retracted in neutral position, should
advance after pushing an easily pressed button (S1). Note: for the control of a large
volume cylinder (with a large piston diameter) an accordingly dimensioned directional
control valve is necessary. The cylinder is mounted a slight distance from the button
(S1). After releasing the manual pushbutton, the piston of the cylinder should retract
automatically into its back position.
Additions to the circuit diagram. All connections should be marked with the port symbols
according to ISO 5599 or RP 68 P.
Pneumatic circuit diagram: A manually operated 3/2 directional control valve in closed
neutral position (start button S1) applies pressure to a pneumatically operated 3/2
directional control valve. A large volume single-acting cylinder is controlled via a
pneumatically operated 3/2 directional control valve (pos. 9), the piston rod extends.

Exercise 03 - Speed Control of Single Acting Cylinder–Slow Speed

Extension and Rapid Retraction
Aim: On actuation of a manual push button a Single acting cylinder should advance and return to
initial position after releasing the push button. The forward speed of the cylinder should be slow
and controllable. The return speed should be faster than the nominal speed.

In addition to throttling the cylinder speed, this exercise shows how to achieve the highest
possible speed when retracting the piston rod by using a quick-exhaust valve.

Suggestion for the positioning of equipment on the working plate

Table: List of Equipment

03 Single acting Cylinder (Z1)

16 Quick Exhaust Valve
15 One way flow control valve
07 3/2 way Push button valve (NC)
02 Distributor manifold ( 6 fold)
01 Air Service unit (Filter Regulator assembly)
Pneumatic circuit diagram

Fig. 01: Pneumatic Circuit diagram: Speed Control of Single Acting Cylinder–Slow Speed Extension and Rapid Retraction

Task: The piston rod of a large volume, single-acting cylinder (Z1) is to extend with restricted,
adjustable speed. The retraction of the piston rod should occur at the highest possible
speed, also when the directional control valve (S1) is mounted a distance away from the
cylinder. The cylinder is controlled by a manually operated button (S1). After releasing
the button, the piston rod should retract automatically into its back position.
Additions to the circuit diagram. All connections should be marked with the connection
symbols according to ISO 5599 or RP 68 P. Pneumatic circuit diagram Via the flow
control valve with no return mounted in the working line the speed of the piston rod when
extending can be infinitely restricted. Through the quick-exhaust valve, also mounted in
the working line (as near to the cylinder port as possible), the cylinder piston retracts with
the maximum possible speed.
Exercise 04 - Position Dependent Control of a Double Acting Cylinder
with Mechanical Limit Switches
Aim: The displacement-dependent control of a double-acting cylinder by using limit switches is
demonstrated in this exercise
Task: A Double acting cylinder is required to perform continuous reciprocating motions on actuation
of a detent manual push button. The piston should extend and retract over the complete stroke length
as interrogated by mechanical limit switches. The speed of travel of the piston should be adjustable
both during the forward and return motions

Suggestion for the positioning of equipment on the working plate

Table: List of Equipment

04 01 Double acting Cylinder (Z1)
11 01 Double Piloted 5/2 way Valve
15 02 One way flow control valves
06 01 3/2 way Push button valve (NC) with detent
13 02 3/2 way roller lever N.C. valve [Limit switches]
02 01 Distributor manifold ( 6 fold)
01 01 Air Service unit (Filter Regulator assembly)
 Pneumatic circuit diagram

Pneumatic circuit diagram

If the start button (S0) is actuated and the feeler roll (S1) mounted in the back end position of
the cylinder (Z1) is also actuated, then the signal reaches port 14 of the impulse valve and
switches it over, extending the piston rod. If limit switch S2 is contacted by the piston rod
plunger, the signal arrives at port 12 of the impulse valve, the impulse valve switches back to the
right switch position, the piston retracts. The limit switch S1 is actuated in the back end position
of the piston; now the control is ready for a new start. The speed of both cylinder movements is
infinitely adjusted with the flow control valves with non-return.
Exercise 06 – Experiments on AND, OR, Latch and Electric limit
Switch

Aim: To conduct experiment on the logical “AND function” in relay technology.

Task:
The piston rod of the double-acting cylinder (Z1) should then extend when push button
S1”AND” push button S2 are actuated. Push buttons S1 and S2 switch the valve solenoid
indirectly via relay contacts. The pneumatic circuit diagram is to be drawn up using symbols and
port identification symbols according toISO1219 and RP68P.The detached representation of the
electric circuit diagram is to be presented with the circuit symbols of electrical equipment
according to DIN/ISO.

Positioning of equipment on the working plate

Pneumatic circuit diagram
When voltage is present at the valve solenoid Y1 (14) of the spring return 5/2 directional control
valve, the piston rod of the double-acting cylinder Z1 extends and remains extended as long as
the voltage is present at the valve solenoid.

Electric circuit diagram

· The operating voltage is turned on with control switch S0. The relay coils K1 and K2 and the
valve solenoid Y1 are connected to the 0V potential at the bottom bus bar.
· Push button S1 switches relay K1, push button S2 switches relay K2.
· When the contact of K1”AND” the contact of K2 close, the 24 V + voltage potential reaches
the upper port of the valve solenoid Y1, the solenoid valve switches.

Presentation of the Value Table

· Logical functions such as the logical basic functions” AND” can be presented in value tables.
· The basis for this form of presentation is binary digital technology: signals can only occupy the
conditions 0 (off) or 1 (on).
Aim: To conduct experiment on the logical “OR function” in relay technology.

Task:
· The piston rod of the double-acting cylinder (Z1) should then extend when push button
S1”OR” push button S2 is actuated.
· Push buttons S1 and S2 switch the valve solenoid indirectly via relay contacts.
· The pneumatic circuit diagram is to be drawn up using symbols and port identification symbols
according to ISO 1219 and RP68P
· The detached representation of the electric circuit diagram is to be presented with the circuit
symbols of electrical equipment according to DIN/ISO.

Positioning of equipment on the working plate

Pneumatic circuit diagram
When voltage is present at the valve solenoid Y1 (14) of the spring return 5/2 directional control
valve, the piston rod of the double-acting cylinder Z1 extends and remains extended as long as
the voltage is present at the valve solenoid.

Electric circuit diagram

· The operating voltage is turned on with control switch S0.
· The relay coils K1 and K2 and the valve solenoid Y1 are connected to the 0V potential at the
bottom bus bar
· Push button S1 switches relay K1, push button S2 switches relay K2.
· If the contact of K1”OR” the contact of K2 closes, the 24 V + voltage potential reaches the
upper port of the valve solenoid Y1, the solenoid valve switches.

Presentation of the Value Table

· Logical functions such as the logical basic functions” OR” can be presented in value tables
· The basis for this form of presentation is binary digital technology: signals can only occupy the
conditions 0 (off) or 1 (on).
Aim: To conduct experiment on the logical “LATCH function” in relay technology.

Positioning of equipment on the working plate

Pneumatic circuit diagram
When voltage is present at the valve solenoid Y1 (14) of the spring return 5/2 directional control
valve, the piston rod of the double-acting cylinder Z1 extends and remains extended as long as
the voltage is present at the valve solenoid.
Electric circuit diagram 1 (dominant” off”)
· The operating voltage is turned on with control switch S0. The relay coils K1 and valve
solenoid Y1 are connected to the 0V potential at the bottom bus bar. · When push button S1
(normally open contact) is briefly actuated, via push button S2 (normally closed contact), which
is not actuated, to relay K1
· The normally open contact in current path 2 closes parallel to push button S1 and constitutes
the latching circuit for relay coil K1
· The normally open contact K1 in current path 3 closes simultaneously; the valve solenoid Y1
receives voltage.
· Additional requirement: when both push buttons are actuated simultaneously, K1 has no
voltage; the latching circuit dominates in favor of” off”.
Electric circuit diagram 2 (dominant” on”)
· When push button S1 (normally open contact) is briefly actuated, 24 V + voltage potential
reaches relay coil K1, the normally open contact K1 in current path 2 forms the latching circuit
of K1 in a serial connection with the normally closed contact push button S2, which has not been
actuated. · Simultaneously the normally open contact K1 in current path 3 closes and switches
the valve solenoid Y1.
· Additional requirement: if both push buttons are actuated at the same time, relay coil K1 only
receives voltage via S1, the latching circuit dominates in favor of ”on”.
Electric circuit diagram 3 Safety circuit, dominant” off”
· The + voltage for the complete circuit is supplied by normally closed contact S1 only.
· Thus the complete circuit can be switched dead via S1. The latching circuit and the valve
solenoid Y1 are switched via the contact K1.
· When push buttons S1 and S2 are simultaneously actuated, then the complete circuit is always
powerless, the circuit can then be described as dominant” off”.
Aim: To conduct experiment on the logical “Electric Limit Switch function” in relay
technology.
Objective: Displacement-dependent control of a double acting cylinder with 1 electric limit
switch
In this displacement-dependent control of a double-acting cylinder, a mechanically controlled
electric auxiliary switch (changeover contact) is used. The actuator is an electrically controlled
5/2 directional control valve with spring return.

Positioning of equipment on the working plate

Task
”Separating workpieces”
· Workpieces coming from a transfer system are to be separated.
· The piston rod of a double-acting cylinder Z1 extends after briefly actuating push
button S1, separates the workpieces and retracts automatically after reaching the front end
position
· An electrically controlled spring return 5/2 directional control valve is to be used as an actuator.
· The extension speed should be infinitely adjustable.
· An electric limit switch with changeover contact is available for use
· The functional diagram is to be drawn up and the pneumatic circuit Diagram to be
supplemented.
· The detached representation of the electric circuit diagram is to be drawn up using the circuit
symbols of electrical equipment according to DIN/ISO.
Pneumatic circuit diagram
· When voltage is present at valve solenoid Y1 (14) of the spring return 5/2 directional control
valve, the piston rod of the double-acting cylinder Z1 extends and remains extended as long as
the voltage is present at the valve solenoid
· The extension speed can be infinitely adjusted with a one-way flow control valve.
Electric circuit diagram
· When pushbuttonS1 (Normally open contact) is briefly actuated, +voltage reaches the limit
switches S2 via the normally closed contacts which has not been actuated and relay K1 switches.
· The normally opened contact K1 in current path 2 closes and creates the latching circuit for
relay K1.
· The second normally opened contact K1 in current path 3 switches the valve solenoid Y1.
· Only when limit switch S2 is actuated does the normally open contact open, interrupting the
latching circuit and relay K1 de-energizes. Contact K1 in current path 3 interrupts the voltage to
valve solenoid Y1.