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TRAINING MANUAL
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PNEUMATICS
PROJECT EXERCISES
Exercise 1
Direct control of Double Acting Cylinder
Task: 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
automatically
Condition: It is required that force should be exerted both during forward and return motion
Suggestion for the positioning of equipment on the working plate
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)
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Pneumatic circuit diagram
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 or RP 68 P.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 (pos. 8). The spring cushioning mounted
in the cylinder can be adjusted.
Fig. 01: Pneumatic Circuit diagram: Direct control of double acting cylinder
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PNEUMATICS
Exercise 2
Indirect control of Double Acting Cylinder
Task: On actuation of a manual push button a Double acting cylinder with large volume hasto advance. After releasing the push button the cylinder should automatically return to home
position
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)
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PNEUMATICS
Pneumatic circuit diagram
Selection: A Double acting cylinder has to be selected to meet the condition. A single piloted
valve can satisfy the task.
Aim
This exercise demonstrates the indirect control of a double-acting cylinder with a
pneumatically operated 5/2 directional control valve.
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 shouldretract automatically to its back position. Additions to the circuit plan. All connections should
be marked with the connection symbols according to ISO 5599 or RP 68 P.
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.
Fig. 01: PneumaticCircuit diagram: Indirect control of double acting cylinder
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TRAINING MANUAL
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PNEUMATICS
Exercise 2
Indirect control of Single Acting Cylinder
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)
Aim
This exercises conveys know-how on the indirect control of cylinders, using a single-acting
cylinder and a pneumatically operated 3/2 directional control valve as an example
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Pneumatic circuit diagram
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 portsymbols 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.
Fig. 01: PneumaticCircuit diagram: Indirect control of single acting cylinder
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PNEUMATICS
Exercise 3Speed Control of Single Acting CylinderSlow Speed Extension and
Rapid Retraction
Task: 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.
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)
Aim
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.
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Pneumatic circuit diagram
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.
Fig. 01: PneumaticCircuit diagram: Speed Control of Single Acting CylinderSlow Speed Extension and Rapid
Retraction
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PNEUMATICS
Exercise 4
Position Dependent Control of a Double Acting Cylinder with Mechanical
Limit Switches
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)
Aim
The displacement-dependent control of a double-acting cylinder by using limit switches is
demonstrated in this exercise
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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.
Fig. 01: PneumaticCircuit diagram: Position Dependent Control of a Double Acting Cylinder
with Mechanical Limit Switches
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PNEUMATICS
Exercise 5
Logical Control with Shuttle and Twin-Pressure Valves
Task: The Piston of double acting cylinder of a supply station supplies work pieces under the
following logical conditions: The start button (S0) or an auxiliary button (S1) is actuated and
parts are available in the work piece magazine (B2) An optical display shows whether there
are still enough parts available in the magazine. The cylinder should only retract into its back
end position if it has actuation reached the front end position and an acknowledgement button
(S4) is actuated. A 5/2 impulse valve is used as an actuator. Additionally: for scanning work
pieces in the magazine (B2) it is not possible to use a mechanically operated signaler. The
scanning should therefore occur in a non-contact manner through a reflex sensor. The
working speed of the cylinder should be infinitely adjustable in both.
Aim
This exercise uses a logical control to demonstrate the use of the logic basic functions OR
(shuttle valve) or AND (two-pressure valve) in pneumatics. In this exercise, a proximity
switching signaling element (reflex nozzle) is also used.
Pneumatic circuit diagram
Signal pressure then reaches the control line 14 of the actuating drive (piston extends) ifthe
following conditions prove true: the button S0 OR the button S1 is actuated, AND the reflexnozzle B2 (amplifier pos. 26) has switched. Signal pressure then reaches the control line 12
(piston retracts) of the actuating drive ifthe limit switch S3 AND the button S4 are actuated.
The reflex nozzle is supplied with low pressure of 0.4 bar via the pressure regulating valve
with filter pos. 24. The pneumatic pressure display indicates whether the reflex nozzle or the
amplifier is supplying a signal.
Example of application
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TRAINING MANUAL
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PNEUMATICS
Suggestion for the positioning of equipment on the working plate
Table: List of Equipment
Position Qty Description of component
04 01 Double acting Cylinder (Z1)
11 01 5/2 double Piloted Valve
13 02 3/2 way D.C. Valve (N.C.) Roller operated
18 01 Shuttle Valve, OR
19 02 Two Pressure Valves, AND
20 01 Pressure display,pneumatic,red,minimum pressure1.2bar
24 01 Pressure regulator with filter and regulator
25 01 Reflex Nozzle
26 01 Pneumatic Amplifier
15 02 One way flow control valves
07 01 3/2 way Push button valve (NC)
02 01 Distributor manifold ( 6 fold)
01 01 Air Service unit (Filter Regulator assembly)
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PNEUMATICS
Single and multiple OR or AND circuits with shuttle and twin pressure valve
Pneumatic circuit diagram
Fig. 01: Pneumatic circuit diagram
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PNEUMATICS
Exercise 6
Sequential Control of two double acting cylinders without overlapping
signals
Suggestion for the positioning of equipment on the working plate
Functional diagram
Aim
This exercise helps to understand sequential controls and provides practical knowledge of
setting up and commissioning a control system with two pneumatic drives. Practice in
developing sequential diagram and pneumatic circuit diagram is exercised.
Functional diagram
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PNEUMATICS
Example of application
Task: Transport of Work pieces
Statement of the Application
The Work pieces coming in on the right roller conveyor should be elevated and sent in a new
direction. After actuating the start button, the piston of cylinder raises the work pieces to the
height of the second roller conveyor with its elevating platform. Cylinder 1 remains in this
position until cylinder 2 has pushed the work pieces from the elevating platform onto upper
roller conveyor. When cylinder 2 has securely pushed all the work pieces onto the upperRoller conveyor, cylinder 1 moves down again only when cylinder has retracted into its lower
end position does cylinder 2 also retract. Additionally a new start is only possible when
cylinder is actually in its back end position.
The working speed of both cylinders should be infinitely adjustable in both Directions the
functional diagram is to be developed with actuator and drive element. Draw the circuit
diagram with port symbols according to ISO 5599.
Functional Diagram
The Status of the cylinder displacement and actuation of set and reset signals at the A doublepiloted directional control valve is shown in the Functional Diagram: Above In order to meet
all the requirements a Pneumatic control circuit can be developed as shown below.
Example of application
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PNEUMATICS
Table: List of Equipment
Position Qty. Description of components
04 02 Double-acting Cylinders (Z1 and Z2)
11 02 5/2 Way Directional Control Valves (Double piloted)
15 02 One way Flow control Valves (adjustable)
06 01 3/2 way Push button valve (NC)(S0)
13 04 3/2 way roller lever Limit switch (S1,S1,S3,S4)
02 01 Distributor manifold ( 6 fold)
01 01 Air Service unit (Filter Regulator assembly)
Pneumatic circuit diagram
Fig. 01: Pneumatic circuit diagram
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PNEUMATICS
Task
"Transport of Workpiece"
The workpieces coming in on the right roller conveyor should be elevated and sent in a new
direction. After actuating the start button (S0) the piston of cylinder 1 (Z1) raises theworkpieces to the height of the second roller conveyor with its elevating platform. Cylinder 1
(Z1) remains in this position until cylinder 2 (Z2) has pushed the workpieces from the
elevating platform onto the upper roller conveyor. When cylinder 2 (Z2) has securely pushed
all the workpieces onto the upper roller conveyor, cylinder 1 (Z1) moves down again. Only
when cylinder 1 (Z1) has retracted into its lower end position does cylinder 2 (Z2) also
retract. Additionally: a new start is only possible when cylinder 2 (Z2) is actually in its back
end position.
The working speed of both cylinders should be infinitely adjustable in both directions. The
functional diagram is to be developed with actuator and drive element. Drawing up the circuitdiagram with symbols and port symbols according to ISO 5599 or RP 68 P.
Pneumatic circuit diagram
Two double-acting cylinders, retracted in neutral position, are displacement-dependently
controlled by impulse valves. After actuating the start button S0, a control signal arrives at
port 14 of the impulse valve for cylinder Z1 via the actuated limit switch S3. The piston rod
of cylinder Z1 extends and in its front end position actuates the limit switch S2. The limit
switch S2 sends a signal to the control port 14 of the impulse valve for cylinder 2. The piston
rod of cylinder 2 extends into the front end position and actuates the limit switch S4. The
limit switch S4 delivers the control signal to port 12 from the impulse valve for cylinder Z1.The piston of cylinder Z1 retracts and in its back end position actuates limit switch S1. The
limit switch S1 delivers a signal to port 12 from the impulse valve for cylinder Z2, the piston
retracts to the back end position. The system control is in its initial position.