Sensors in pneumatics

Workbook TP 240

With CD-ROM

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Festo Didactic 566910 EN

Order number: Revision level: Authors: Graphics: Layout:

566910 11/2009 Frank Ebel, Markus Pany Doris Schwarzenberger 02/2010, Beatrice Huber, Frank Ebel

Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2010 Internet: www.festo-didactic.com E-mail: did@de.festo.com The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration.

Table of contents
Use for intended purpose __________________________________________________________________ IV Preface ______________________________________________________________________________ V Introduction ____________________________________________________________________________ VII Work instructions and safety precautions ____________________________________________________ VIII Training package, sensors in pneumatics (TP 240) ______________________________________________X Learning objectives _______________________________________________________________________ XI Allocation of learning objectives per exercise _________________________________________________ XII Equipment set __________________________________________________________________________ XIV Allocation of components per exercise _______________________________________________________ XVI Tools for the trainer _____________________________________________________________________ XVII Structure of the exercises _________________________________________________________________ XIX Component designations __________________________________________________________________ XIX CD-ROM contents ________________________________________________________________________ XX

Exercises and solutions Exercise 1: Automating a feed separator _______________________________________________________1 Exercise 2: Repairing a transfer unit ___________________________________________________________7 Exercise 3: Commissioning a test device _____________________________________________________ 15 Exercise 4: Tensioning a belt _______________________________________________________________ 26 Exercise 5: Stamping parts ________________________________________________________________ 34 Exercise 6: Clamping boards _______________________________________________________________ 44 Exercise 7: Inspecting plastic bottles ________________________________________________________ 52 Exercise 8: Transferring beverage bottles_____________________________________________________ 60 Exercise 9: Measuring the flow characteristics of a one-way flow control valve ______________________ 66 Exercise 10: Suction monitoring for lenses____________________________________________________ 72

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Use for intended purpose

The training package for sensors in pneumatics may only be used: For its intended purpose in teaching and training applications When its safety functions are in flawless condition The components included in the training package are laid out in accordance with the latest technology, as well as recognised safety rules. However, life and limb of the user and third parties may be endangered, and the components may be impaired if they are used improperly. The training system from Festo Didactic has been developed and manufactured exclusively for training and vocational education in the fields of automation technology. The respective training companies and/or trainers must ensure that all trainees observe the safety precautions which are described in this workbook. Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company and/or any third parties, which occur during use of the set of devices in situations which serve any purpose other than training and/or vocational education, unless such damages have been caused by Festo Didactic due to malicious intent or gross negligence.

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Preface
Festo Didactics training system for automation technology is geared towards various educational backgrounds and vocational requirements. The training system is therefore broken down as follows: Technology oriented training packages Mechatronics and factory automation Process automation and control technology Robotino training and research with mobile robots Hybrid learning factories

The technology packages deal with various technologies including pneumatics, electro-pneumatics, hydraulics, electro-hydraulics, proportional hydraulics, programmable logic controllers, sensor technology, electrical engineering and electric drives.

The modular design of the training system allows for applications which go above and beyond the limitations of the individual packages, such as, for example, PLC actuation of pneumatic, hydraulic and electrical drives.

Festo Didactic GmbH & Co. KG 566910

All training packages have the same, identical structure: Hardware Teachware Software Seminars The hardware is comprised of industrial components and systems that are specially designed for training purposes. The structure of the teachware corresponds to that of the hardware. It includes: Textbooks (with exercises and examples) Workbooks (with practical exercises, supplementary instructions and solutions) Book of exercises (with practical exercises and supplementary explanations) Transparencies and videos (for dynamic instruction) The teaching and learning media are available in several languages. Theyre intended for use in classroom instruction, but are also suitable for self-study. Where software is concerned, computer training programs, as well as simulation, visualisation, project engineering, design engineering and programming software, are made available. A wide range of seminar offerings covering the contents of the training packages round out the programme for training and vocational education.

If you have any suggestions or feedback about this manual, please send us an e-mail at did@de.festo.com. The authors and Festo Didactic look forward to your comments.

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Introduction
This workbook is part of the training system for automation technology from Festo Didactic GmbH & Co. KG. The system provides a solid basis for practice-oriented training and vocational education. Training package TP 240 deals with the subject of sensors in pneumatics. The subject of pressure sensors, flow sensors, analogue position transmitters for pneumatic cylinders, signal converters and sensors for vacuum technology is treated in depth. A permanent workstation equipped with a Festo Didactic profile plate is a prerequisite for setting up the controllers. The profile plate has 14 parallel T-slots at 50 mm intervals. A power supply unit with shortcircuit protection is used as a direct voltage source (input: 230 V, 50 Hz, output: 24 V, max. 5 A). A portable compressor with silencer (230 V, approx. 50 l/min, max. 800 kPa = 8 bar) can be used for compressed air supply. Working pressure should not exceed 600 kPa (6 bar). Ideal control sequence reliability can be achieved by operating the controller at a working pressure of 500 kPa (5 bar) without oil. In addition to equipment set TP 240, youll also need components from equipment set TP 201 in order to complete the 10 exercises. Data sheets for the individual components are also available (cylinders, sensors etc.).

Training materials The book of exercises for this workbook is provided as training material for trainees and pupils: Sensors in pneumatics, order no. 566915

The book of exercises can be ordered separately without the workbook. The worksheets can thus be easily made available to trainees and pupils.

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Work instructions and safety precautions

General Trainees should only work with the circuits under the supervision of a trainer. Observe specifications included in the data sheets for the individual components and in particular all safety instructions! Faults which may impair safety must not be generated in the training environment and must be eliminated immediately. Mechanical setup Only reach into the setup when its at a complete standstill. Mount all the components securely onto the profile plate. Adhere to instructions regarding positioning of the components. Electrical setup Use low voltage only (max. 24 V DC). Electrical connections must only be established and interrupted in the absence of voltage! Only use connecting cables with safety plugs for electrical connections. Only pull the plug when disconnecting connecting cables never pull the cable. Pneumatics Do not exceed the maximum permissible pressure of 600 kPa (6 bar). Do not activate compressed air until all the tubing connections have been completed and secured. Do not disconnect tubing while under pressure. Danger of injury when switching compressed air on! Cylinders may advance and retract automatically. Danger of accident due to tubing slipping off! Use shortest possible tubing connections. Wear safety glasses. In the event that tubing slips off: Switch compressed air supply off immediately. Pneumatic circuit setup: Connect the components with plastic tubing with an outside diameter of 4 or 6 mm. Push the tubing into the push-in connector as far as it will go. Switch compressed air supply off before dismantling the circuit. Dismantling the pneumatic circuit: Press the blue release ring down, after which the tubing can be pulled out.

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Mounting technology The mounting boards for the components are equipped with mounting variant A, B or C: Variant A, snap-in system Lightweight components that are not load-bearing (e.g. directional control valves and sensors). Simply clip the components into the slot on the profile plate. Release components from the slots by actuating the blue lever. Variant B, bolt system Components with medium load capacity (e.g. pneumatic cylinders). These components are clamped onto the profile plate using T-head bolts. The blue, knurled nut is used for clamping and loosening. Variant C, screw system For components with high load capacity and components which are seldom removed from the profile plate (for example on-off valve with filter-regulator). The components are secured with socket head screws and T-head bolts. Recommended accessories A digital multimeter is required in order to evaluate the circuits after setting them up. The following are measured with the digital multimeter: operating voltage, output voltage and output current.

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Training package, sensors in pneumatics (TP 240)

The TP 240 training package consists of a multitude of training materials. The subject matter of this package is sensors in pneumatics. The individual components included in the TP 240 training package can also be included in other packages. Important components of TP 240 Permanent workstation with Festo Didactic profile plate Equipment sets or individual components (e.g. sensors, pneumatic cylinders, set of objects, positioning slide) Complete laboratory setups Media The teachware for the TP 240 training package consists of a textbook, a workbook and a book of exercises. The textbook imparts basic physical and technical knowledge regarding sensors. The workbook includes the exercise sheets as well as the solutions for each of the 10 exercises and a CD-ROM. The book of exercises consists of a complete set of ready-to-use worksheets for each exercise. Data sheets for the hardware components are made available along with the training package, and on the CD-ROM.
Media Textbook Workbook Book of exercises Set of transparencies Digital training program Proximity switches Sensors in pneumatics Sensors in pneumatics Sensor technology WBT for sensor technology 1 Sensors in pneumatics

Overview of media for the TP 240 training package

A digital training program (WBT for sensor technology 1 Sensors in pneumatics) is available as software for training package TP 240. This training program takes an in-depth look at sensors in pneumatic controllers used in automated systems. With the help of a complex example based on actual industrial practice, the learner works through the basic principles of sensor technology and is able to select suitable sensors. Youll find further training materials in our catalogue and on the Internet. The training system for automation technology is continuously updated and expanded. Transparency sets, videos, CD-ROMs, DVDs and training programs, as well as additional teachware, are offered in several languages.

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Learning objectives
Magnetic proximity switches Become familiar with the setup and function of a magnetic proximity switch. Become familiar with proximity switches with which a cylinders end-position can be detected. Become familiar with terminology from the field of proximity switch technology. Become familiar with various types of proximity switches. Become familiar with the setup and function of a magneto-resistive proximity switch. Become familiar with circuit symbols for proximity switches. Learn to select proximity switches for monitoring the end-positions of cylinders. Learn to install and adjust a magnetic proximity switch.

Position transmitters Become familiar with the function and the circuit symbol of a position transmitter. Learn to record and evaluate the characteristic curve of a position transmitter. Become familiar with the range of applications of a position transmitter. Become familiar with the operating mode of a signal converter. Learn to use a signal converter for recording and evaluation.

Pressure sensors Become familiar with the setup and function of a pneumatic-electric converter. Learn to categorise pressure sensors according to the measuring method used. Learn to describe the function of a pressure sensor. Learn to classify the pneumatic connections and electrical terminals of an analogue pressure sensor. Learn to adjust a pressure sensor. Learn to record the characteristic curve of a pressure sensor. Become familiar with the setup and function of pressure sensors. Become familiar with the terminology used to describe the switching characteristics of sensors. Learn to use a pressure sensor to detect leaks. Become familiar with the setup and function of a vacuum switch. Learn to select and adjust a vacuum switch for a given application.

Flow sensors Become familiar with the setup and function of a flow sensor. Learn to record the characteristic curve of a one-way flow control valve. Learn to record the characteristic curve of a flow sensor. Become familiar with the range of applications of flow sensors.

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Allocation of learning objectives per exercise

Exercise Learning objectives Become familiar with the setup and function of a magnetic proximity switch. Become familiar with proximity switches with which a cylinders end-position can be detected. Become familiar with terminology from the field of proximity switch technology. Become familiar with various types of proximity switches. Become familiar with the setup and function of a magneto-resistive proximity switch. Become familiar with circuit symbols for proximity switches. Learn to select proximity switches for monitoring the end-positions of cylinders. Learn to install and adjust a magnetic proximity switch. Become familiar with the function and the circuit symbol of a position transmitter. Learn to record and evaluate the characteristic curve of a position transmitter. Become familiar with the range of applications of a position transmitter. Become familiar with the operating mode of a signal converter. Learn to use a signal converter for recording and evaluation. Become familiar with the setup and function of a pneumatic-electric converter. Learn to categorise pressure sensors according to the measuring method used. Learn to describe the function of a pressure sensor. Learn to classify the pneumatic connections and electrical terminals of an analogue pressure sensor. Learn to adjust a pressure sensor. 1 2 3 4 5 6 7 8 9 10

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Exercise Learning objectives Learn to record the characteristic curve of a pressure sensor. Become familiar with the setup and function of pressure sensors. Become familiar with the terminology used to describe the switching characteristics of sensors. Learn to use a pressure sensor to detect leaks. Become familiar with the setup and function of a vacuum switch. Learn to select and adjust a vacuum switch for a given application. Become familiar with the setup and function of a flow sensor. Learn to record the characteristic curve of a oneway flow control valve. Learn to record the characteristic curve of a flow sensor. Become familiar with the range of applications of flow sensors.

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Equipment set
The equipment set TP 240 expands the learning contents of training package TP 201 by including the subject of sensors in pneumatics. The expanded contents range from the use of pressure and flow sensors, as well as analogue position transmitters including the integration of signal converters, up to sensors for vacuum technology. The components from the TP 201 package are required for the implementation of projects.

Equipment set for sensors in pneumatics (TP 240), order no. 566908
Component Pressure regulator with pressure gauge Signal converter for position transmitter Electronic pressure sensor, 0 to 10 bar Pressure switch, 0 to -1 bar Flow sensor, -1 to 1 l/min., analogue Flow sensor, 0.5 to 10 l/min., analogue Vacuum generator Limit stop, adjustable Double-acting profile cylinder Position transmitter, 0 to 50 mm, analogue Suction gripper, 10 mm diameter One-way flow control valve Order no. 539756 548621 548622 548624 548625 548626 548628 548630 549832 560124 560158 560159 Quantity 1 1 1 1 1 1 1 1 1 1 1 1

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Graphic symbols, equipment set

Component Pressure regulator with pressure gauge Graphic symbol ISO 1219-1 Component Electronic pressure sensor, 0 to 10 bar Graphic symbol EN 60617-7

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Vacuum generator

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Pressure switch, 0 to -1 bar

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Double-acting profile cylinder

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Suction gripper, 10 mm diameter

ISO 1219-1

Flow sensor, -1 to 1 l/min., analogue

EN 60617-7

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Signal converter for position transmitter

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Flow sensor, 0.5 to 10 l/min., analogue

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Position transmitter, 0 to 50 mm, analogue

EN 60617-7

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Allocation of components per exercise

Note Exercise 1 is a theoretical exercise for which no components are required.

TP 240 equipment set

Exercise Component Pressure regulator with pressure gauge Signal converter for position transmitter Electronic pressure sensor, 0 to 10 bar Pressure switch, 0 to -1 bar Flow sensor, -1 to 1 l/min., analogue Flow sensor, 0.5 to 10 l/min., analogue Vacuum generator Limit stop, adjustable Double-acting profile cylinder Position transmitter, 0 to 50 mm, analogue Suction gripper, 10 mm diameter One-way flow control valve 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10

TP 201 equipment set

Exercise Component One-way flow control valve Proximity switch, electronic 5/2-way solenoid valve with LED Pressure sensor with display Signal input, electrical Relay, 3-wayf Distributor block On-off valve with filter-regulator 1 1 1 1 1 1 1 1 2 2 1 1 2 2 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10

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Optional components
Exercise Component Digital multimeter Ruler 24 V DC power supply unit 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10

Tools for the trainer

Learning objectives The basic learning objective of this workbook is to become familiar with sensors in pneumatics, as well as the practical setup of circuits on the profile plate. This direct interaction involving both theory and practice ensures faster progress and longer-lasting learning. The more specific learning objectives are documented in the matrix. Concrete, individual learning objectives are assigned to each exercise. Required time The time required for working through the exercises depends on the learners previous knowledge of the subject matter. For apprentices in the field of metalworking or electrical installation the time required is approx. 2 weeks. For a skilled labourer it is approx. 1 week Equipment set components The workbook, the book of exercises and the equipment set match each other. Youll need the components included in the TP 240 device set for all 10 exercises. Youll also need some of the components from the TP 201 device set. Each exercise can be set up on a profile plate with a width of at least 350 mm. Standards The following standards are used in this workbook: DIN ISO 1219-1: Fluid power systems and components Graphic symbols and circuit diagrams EN 60617-7: Graphical symbols for circuit diagrams EN 61346-2: Industrial systems, installations and equipment and industrial products Structuring principles and reference designations Identification within the workbook Solutions and supplements in graphics or diagrams appear in red.

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Identification within the book of exercises Texts which require completion are identified with blank lines or grey table cells. Graphics which require completion include a grid. Training notes These notes provide additional information about the individual proximity switches. They are not included in the book of exercises. Solutions The solutions in the workbook are the results of test measurements. The results of your measurements may deviate from these. Learning topics The table below contains an overview of the learning topics offered by educational institutions on the subject matter of sensors for object detection, broken down by profession.
Vocation Electrician for automation technology Subject matter Analysing and adapting controllers Systems analysis and safety testing Programming and implementing controllers for systems Selecting and integrating drive systems Commissioning and approving automation systems Maintaining and optimising automation systems Mechatronics technician Implementing mechatronic subsystems Commissioning, troubleshooting and repair Industry mechanic Installing and commissioning control systems

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Structure of the exercises

All 10 exercises have the same structure and are broken down into: Title Learning objectives Presentation of the problem Layout Project assignment Work tools Worksheets The workbook includes the solutions for all 10 exercises.

Component designations
Pneumatic components are designated in circuit diagrams in accordance with DIN-ISO 1219-2. All the components included in any given circuit have the same primary identifying number. Letters are assigned depending on each respective type of component. Consecutive numbers are assigned if several components of the same type are included within a single circuit. Pressure lines are designated with a P and are numbered separately. Cylinders: Valves: Sensors: Signal input: Accessories: 1A1, 2A1, 2A2 ... 1V1, 1V2, 1V3, 2V1, 2V2, 3V1 ... 1B1, 1B2 ... 1S1, 1S2 ... 0Z1, 0Z2, 1Z1 ...

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CD-ROM contents
Included on the CD-ROM are the workbook (in PDF format) as well as additional media. The CD-ROM contains the following folders: Operating instructions Images Data sheets Presentations Product information Operating instructions Operating instructions for various components included in the training package are available. These instructions are helpful when using and commissioning components. Images Photos and graphics of components and industrial applications are made available. These can be used to illustrate individual tasks or to supplement project presentations. Data sheets The data sheets for the components included in the training package are supplied along with the equipment set and are also available as PDF files. Presentations This directory contains short presentations for the components included in the training package. They can be used, for example, to create project presentations. Product information The manufacturers product information is provided for selected components. The representations and descriptions of the components in this format are intended to demonstrate how they are presented in an industrial catalogue. Additional information regarding the components is also included.

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Exercise 1 Automating a feed separator

Learning objectives After completing this exercise: Youll be familiar with the setup and function of a magnetic proximity switch. Youll be familiar with proximity switches with which a cylinders end-position can be detected. Youll be familiar with terminology from the field of proximity switch technology. Youll be familiar with various types of proximity switches.

Presentation of the problem Workpieces are transported to a processing unit on a conveyor belt. The workpieces have to be separated upstream of the processing unit. The separating cylinders end positions are monitored using magnetic proximity switches.

Layout

Feed separator

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Exercise 1 Automating a feed separator

1. 2. 3. 4. 5.

Project assignment Describe the function of a magnetic proximity switch. Select a suitable proximity switch for monitoring the end position of a cylinder. Explain terminology from the field of proximity switch technology. Determine whether or not a solenoid valve can be directly actuated by a proximity switch. Describe different types of proximity switches.

Work tools Data sheets

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Exercise 1 Automating a feed separator

Setup and function of a magnetic proximity switch Describe the setup and function of a magnetic proximity switch (reed switch). Reed switches are magnetically actuated proximity switches. They consist of two contact reeds which are located in a glass tube which is filled with inert gas. When a magnetic force is applied, the two reeds make contact allowing electrical current to flow. In the case of reed switches which function as NC contacts, the contact blades are preloaded with small magnets. This preloading is overpowered by the significantly stronger switching magnet. Reed switches have a long service life and minimal switching times (approx. 0.2 ms). Theyre maintenance-free, but mustnt be used at locations with strong magnetic fields (e.g. in proximity to resistance welding units).

Sensing the end position of a pneumatic cylinder The front end-position of a drive cylinder is to be sensed with a proximity switch. The output signal from the proximity switch will be processed with a programmable logic controller. Any of the proximity switches listed below can be selected. Select suitable proximity switches and explain how the specified requirements are fulfilled. Pneumatic proximity switch Reed proximity switch Inductive proximity switch A pneumatic limit switch generates a pneumatic output signal which cannot be processed by the electronic controller. Proximity switches are contactless and require no mechanical actuation. Proximity switches are insensitive to contamination. The magnetic field of a permanent magnet attached to the pneumatic cylinders piston can be sensed by Reed proximity switches. As the piston rod and the trip cam are made of metal, inductive proximity switches can be used.

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Exercise 1 Automating a feed separator

Terminology from the field of proximity switch technology. The output switching characteristics of proximity switches are frequently specified in data sheets with the abbreviations NO and NC. Explain the meanings of these terms. NO: normally open A sensor is designated NO (normally open) when it reads logic 0 (zero voltage) in the normal state (no object detected). Logic 1 is only transmitted to the controller when the sensor detects an object. Seen from a switching technology standpoint, this sensor thus corresponds to normally open contacts. NC: normally closed A sensor is designated NC (normally closed) when it reads logic 1 in the normal state (no object detected). When an object is detected, the switching output transmits logic 0 to the controller. Seen from a switching technology standpoint, this sensor thus corresponds to normally closed contacts.

Characteristic Operating voltage range, DC Switching output Switching element function Max. output current Protection against short-circuit Measuring method Reverse polarity protection Switching status display Response times on/off Max. switching frequency Max. DC switching power Voltage drop Switching point reproducibility

Value 10 to 30 V PNP Normally open contact 200 mA Yes Inductive For all electrical connections Yellow LED 0.5 ms 1000 Hz 6W 1.8 V 0.1 mm

Data sheet for magnetic proximity switch (excerpt)

Determine the output switching characteristics of the magnetic proximity switch with the help of the data sheet, and enter them on the worksheet. The magnetic proximity switch has a PNP output and a normally open output function.

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Exercise 1 Automating a feed separator

Directly actuating a solenoid valve A solenoid valve with spring return will be switched using a magnetic proximity switch.
Characteristic Valve function Actuation type Standard nominal flow rate Operating pressure Design Type of reset Exhaust function Manual override Type of actuation Pilot air supply Response times on/off Coil characteristics Operating medium Pneumatic connection Value 3/2-way, closed, single solenoid Electrical 500 l/min. 200 to 800 kPa Piston spool Pneumatic spring Without flow control Detenting Piloted Internal 20 ms 24 V DC, 1.5 W Dried compressed air, lubricated or unlubricated QS-6

Data sheet for 3/2-way solenoid valve (excerpt)

Calculate how much output current will have to be supplied by the proximity switch in order to switch the solenoid coil. Use the data included in the data sheet for the solenoid valve. Operating voltage is 24 V DC. Power consumption of the coil is 1.5 W. The power equation ( P = U I ) is turned around and current is calculated as follows:
I= P 1.5 W = = 0.0625 A = 62.5 mA 24 V U

Compare the results with the technical data for the magnetic proximity switch and supplement the following data. Switching current of the coil: Maximum proximity switch output current: Maximum proximity switch switching capacity: 62.5 mA 200 mA 6W

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Exercise 1 Automating a feed separator

Can the proximity switch be used to directly actuate the solenoid valve? Which factors must be taken into consideration? Yes, the 3/2-way solenoid valve can be switched using the magnetic proximity switch. To be determined is whether or not the proximity switch can reliably switch the inductive load over long periods of time without a protective circuit.

Types of proximity switches Describe the difference between contactless and contacting proximity switches, and provide an example of each. Contactless proximity switches In the case of contactless proximity switches, no moving contacts are switched. Instead, the sensors output is electronically connected to either supply voltage or earth (= output voltage of 0 V). Examples: Magnetic contactless proximity switches (inductive magnetic, magneto-resistive), inductive proximity switches, capacitive proximity switches, optical proximity switches Contacting proximity switches In the case of contacting proximity switches, the contact blades are closed, for example, when a magnet approaches, so that electrical current is able to flow and the sensors output is connected either to supply voltage or earth (= output voltage of 0 V). Example: Reed switch

What are the advantages of contactless proximity switches compared to contacting proximity switches? Advantages of contactless proximity switches: No contact problems, e.g. bounce Reliable, bounce-free switching characteristics without dual switching points No wear, as opposed to metallic contacts, and thus long service life Insensitive to contamination and vibration

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