CD-ROM included

WorkbookTP 220

CD-ROM included

Festo Didactic

559880 EN

1M1 1M2

1V1 24

351

1A11B2 1B31B1

1

21V2

1

21V3

K1

14 1412 12

11 11

1M1 1M2

7 98

S1 S2

+24 V

0 V

K1 K2

10 11

A1 A1

A2 A2

K2

13 13

14 14

1B31B1

1 2 65

G1-S3_STOP G1-S1_START

1B2

3 4

G1-S2_STOPG1-S3_START

G1-S1_STOPG1-S2_START

Pneumatic drives

2 © Festo Didactic GmbH & Co. KG • 559880

The Festo Didactic Learning System has been developed and produced solely for

vocational and further training purposes in the field of automation and technology.

The company undertaking the training and/or the instructors is/are to ensure that

trainees observe the safety precautions specified in this workbook.

Festo Didactic herewith excludes any liability for damage or injury caused to

trainees, the training company and/or any third party, which may occur if the system

is in use for purposes other than purely for training; unless the said damage/injury

has been caused by Festo Didactic deliberately or through gross negligence.

Order No.: 559880

Status: 01/2009

Authors: Frank Ebel, Jürgen Hasel

Graphics: Frank Ebel, Doris Schwarzenberger

Layout: 01/2008

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 20013

Internet: www.festo-didactic.com

E-Mail: [email protected]

The purchaser shall receive a single right of use which is non-exclusive, non-time-

limited and limited geographically to use at the purchaser's site/location as follows.

The purchaser shall be entitled to use the work to train his/her staff at the

purchaser's site/location and shall also be entitled to use parts of the copyright

material as the basis for the production of his/her own training documentation for

the training of his/her staff at the purchaser's site/location with acknowledgement

of source and to make copies for this purpose. In the case of schools/technical

colleges and training centres, the right of use shall also include use by school and

college students and trainees at the purchaser's site/location for teaching purposes.

The right of use shall in all cases exclude the right to publish the copyright material

or to make this available for use on intranet, Internet and LMS platforms and

databases such as Moodle, which allow access by a wide variety of users, including

those outside of the purchaser's site/location.

Entitlement to other rights relating to reproductions, copies, adaptations,

translations, microfilming and transfer to and storage and processing in electronic

systems, no matter whether in whole or in part, shall require the prior consent of

Festo Didactic GmbH & Co. KG.

Intended use

© Festo Didactic GmbH & Co. KG • 559880 3

Preface ___________________________________________________________ 7

Introduction __________________________________________________________ 9

Safety and operating instructions _______________________________________ 11

Technology package for electropneumatics (TP 200) ________________________ 13

Training aims of advanced level (TP 220) _________________________________ 15

Allocation of training aims and exercises _________________________________ 16

Equipment set of advanced level (TP 220) _________________________________ 18

Allocation of components and exercises __________________________________ 22

Methodological training aids for the trainer _______________________________ 24

Methodological structure of the exercises _________________________________ 25

Designation of equipment _____________________________________________ 26

CD-ROM contents ____________________________________________________ 27

Part A – Exercises

Exercise 1:

Designing a compressed air network (theory) ______________________________ A-3

Exercise 2:

Sizing of the pneumatic power section (theory) ____________________________ A-9

Exercise 3:

Sizing of the pneumatic power section in relation to

the required stroke time (theory) _______________________________________ A-15

Exercise 4:

Sizing of cylinders in relation to

the required speed and given pressure (theory) ___________________________ A-23

Exercise 5:

Sizing of connecting lines for cylinders (theory) ___________________________ A-27

Exercise 6:

Analysing the speed of travel of linear drives (practical exercise) _____________ A-33

Exercise 7:

Reducing costs by means of different pressures for

forward and return strokes (theory) _____________________________________ A-53

Exercise 8:

Reducing costs by means of preventing leakage (theory) ___________________ A-59

Exercise 9:

Analysing the operating behaviour of linear drives (practical exercise) ________ A-63

Exercise 10:

Describing the end position cushioning of linear drives (theory) ______________ A-81

Exercise 11:

Calculating mass moments of inertia (theory) _____________________________ A-87

Contents

Contents


Exercise 12:

Analysing the operating behaviour of semi-rotary drives (practical exercise) ____ A-93

Exercise 13:

Describing the function and actuation of

the Fluidic Muscle (practical exercise) _________________________________ A-107

Exercise 14:

Selecting a Fluidic Muscle (theory) ___________________________________ A-119

Exercise 15:

Comparing standard cylinders and Fluidic Muscles (practical exercise) ______ A-123

Exercise 16:

Evaluation of pneumatic control systems in the event of

a power failure (practical exercise) ___________________________________ A-133

Part B – Fundamentals

1. Pneumatics in automation ______________________________________ B-3

1.1 Overview ____________________________________________________ B-3

1.2 Areas of application for pneumatics _______________________________ B-4

1.3 Comparison with other forms of energy ____________________________ B-6

2. Cost-effectiveness of compressed air equipment ___________________ B-9

2.1 Compressed air costs ________________________________________ B-10

2.2 Example of correct use of compressed air ________________________ B-12

2.3 Example of incorrect use of compressed air _______________________ B-13

2.4 Cost of leakage in compressed air networks ______________________ B-15

3. Compressed air distribution and service units ____________________ B-17

3.1 Air distribution ______________________________________________ B-17

3.2 Sizing of lines _______________________________________________ B-20

3.3 Service unit ________________________________________________ B-24

4. Pneumatic drives ____________________________________________ B-33

4.1 Linear drives ________________________________________________ B-34

4.2 Semi-rotary drives ___________________________________________ B-41

4.3 Fluidic Muscle ______________________________________________ B-45

5. Optimisation of power section _________________________________ B-51

5.1 Structure and design of a compressed air system __________________ B-51

5.2 Working cylinders ___________________________________________ B-55

5.3 Reducing costs by means of using smaller valves __________________ B-64

Contents


Part C – Solutions

Exercise 1:

Designing a compressed air network – solution ____________________________ C-3

Exercise 2:

Sizing of the pneumatic power section – solution ___________________________ C-7

Exercise 3:


the required stroke time – solution _____________________________________ C-11

Exercise 4:


the required speed and given pressure– solution __________________________ C-17

Exercise 5:

Sizing of connecting lines for cylinders – solution _________________________ C-19

Exercise 6:

Analysing the speed of travel of linear drives – solution ____________________ C-23

Exercise 7:


forward and return strokes – solution ___________________________________ C-37

Exercise 8:

Reducing costs by means of preventing leakage – solution __________________ C-41

Exercise 9:

Analysing the operating behaviour of linear drives – solution ________________ C-43

Exercise 10:

Describing the end position cushioning of linear drives – solution ____________ C-55

Exercise 11:

Calculating mass moments of inertia – solution ___________________________ C-59

Exercise 12:

Analysing the operating behaviour of semi-rotary drives – solution ___________ C-63

Exercise 13:


the Fluidic Muscle – solution __________________________________________ C-71

Exercise 14:

Selecting a Fluidic Muscle – solution ____________________________________ C-77

Exercise 15:

Comparing standard cylinders and Fluidic Muscles – solution ________________ C-79

Exercise 16:


a power failure – solution _____________________________________________ C-83

Contents


Part D – Appendix

Organiser _________________________________________________________ D-2

Mounting technology ________________________________________________ D-3

Plastic tubing _______________________________________________________ D-4


The Festo Didactic Learning System for Automation and Technology is designed to

meet a number of different training and vocational aims. The training packages are

therefore structured on this basis as follows:

Basic packages convey basic knowledge covering all areas of technology

Technology packages address the major topics of open and closed-loop control

technology

Function Packages explain the basic functions of automated systems

Application packages facilitate vocational and further training orientated towards

industrial practice

Technology packages deal with the following technologies: pneumatics,

electropneumatics, programmable logic controllers, hydraulics, electrohydraulics,

proportional hydraulics and electric drive technology.

Preface

Preface


The modular design of the learning system facilitates applications that extend

beyond the limits of the individual packages such as PLC actuation of pneumatic,

hydraulic and electrical drives.

All training packages are of identical structure:

Hardware

Teachware

Software

Seminars

The hardware consists of didactically designed industrial components and systems.

The didactic-methodological framework of teachware is harmonised with the

training hardware and comprises:

Textbooks (with exercises and examples)

Workbooks (with practical exercises, supplementary notes and solutions)

Overhead transparencies and videos (to create an interesting training

atmosphere)

The teaching and training media is available in several languages and is designed for

use in lessons and also for self-tuition.

In terms of software, computer-based training programs (WBTs), simulation

software and programming software are available for programmable logical

controllers.

A comprehensive range of courses dealing with the topics of the various technology

packages completes the range of vocational and further training.


This workbook is a component part of the Learning System for Automation and

Technology from Festo Didactic GmbH & Co. KG. The system provides a solid basis

for practice-oriented vocational and further training.

TP 220 supplements the training packages TP 201 and TP 202 with the fundamentals

of pneumatic drives. The training contents deal with the selection and sizing of

various advanced types of drive taking into consideration special characteristics as

well as commercial and safety-related aspects.

The prerequisite for the assembly of control systems is a fixed workstation equipped

with a Festo Didactic profile plate. The profile plate consists of 14 parallel slots

spaced 15 mm apart. A DC voltage supply is provided via a short-circuit-proof power

supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A). A mobile, silenced

compressor (230 V, approx. 50 l/min, maximum 8 bar = 800 kPa) may be used for

compressed air supply.

The maximum working pressure to be used is p = 6 bar (600 kPa).

Optimum reliability is obtained by operating the control system with unlubricated

compressed air at a working pressure of p = 5 bar (5oo kPa).

You will need the components of equipment sets TP 101, TP 201 and TP 202 for the

practical implementation of the exercises.

The theoretical fundamentals to help you understand this collection of exercises can

be found in Part B of this workbook.

Also available are data sheets in respect of the individual devices (cylinders, valves,

measuring devices).

Introduction

Introduction



In the interest of your own safety you should observe the following instructions:

Pressurised air lines that become detached can cause accidents. Switch off the

supply immediately. Festo Didactic recommends the use of safety glasses when

carrying out the exercises of the technology packages Pneumatics (TP 100) and

electropneumatics (TP 200).

Select a tubing length so as to enable you to establish the shortest distance

between two connections.

Connect the tubing first, before switching on the compressed air.

Caution!

Cylinders may advance as soon as the compressed air is switched on.

Do not operate roller lever valves manually during fault finding. Use a tool.

Limit switches must be mounted laterally to the cam (not from the front).

Do not exceed the permissible working pressure (see data sheets).

Pneumatic circuit design:

Connect the plastic tubing with 4 mm/6 mm OD o the devices by plugging the

tubing into the connector. No additional securing required!

Switch off the compressed air supply prior to dismantling the circuit.

Dismantling of the pneumatic circuit:

Press the blue releasing ring to remove the tubing.

Observe the specifications in the data sheets for the individual devices.

Safety and operating instructions

Safety and operating instructions


The mounting plates of the devices are equipped with mounting variants A, B

or C:

Variant A, latching system

For lightweight, non-loadable devices (e.g. directional control valves). Simply clip

the device into the slot in the profile plate. Devices can be released by pressing

the blue lever.

Variant B, rotary system

For medium, weight loadable devices (e.g. actuators). These devices are clamped

onto the profile plate by means of T-head screws. Clamping and releasing is

achieved by means of a blue knurled nut.

Variant C, screw system

For heavy, loadable devices rarely removed from the profile plate (e.g. on/off

valve with filter regulator).These components are mounted by means of socket

head screws and T-head bolts.

The function generator is used for the evaluation of the assembled control

system, and

– to measure travel times of the linear drive and semi-rotary drive and

– to realise the activation of the fast switching valve.


The technology package TP 200 consists of numerous individual training media as

well as seminars. The subject matter of this package is exclusively electropneumatic

control systems. Individual components from the package TP 200 may also form part

of other packages.

Fixed workstation with Festo Didactic profile plate

Compressor (230 V, 0.55 kW, maximum 8 bar = (800 kPa ))

Equipment set or individual components

Optional training aids

Practical training models

Complete laboratory set-ups

Training documentation

Textbooks Electropneumatics, Basic Level

Fundamentals of pneumatic control technology

Workbooks Basic Level TP 201

Advanced Level TP 202

Advanced Level TP 220

Optional teachware Set of overhead transparencies and overhead projector

Magnetic symbols, drawing template

Training program for electropneumatics

Cutaway model sets 1 + 2 with storage case

Simulation software FluidSIM®

Pneumatics

Measurement software Fluid Lab®

-P

Technology package for electropneumatics (TP 200)

Important components of

TP 200

Technology package for electropneumatics (TP 200)


Seminars

P111 Fundamentals of pneumatics and electropneumatics

P121 Maintenance and fault finding on pneumatic and electropneumatic systems

IW-PEP Maintenance and servicing in control technology – pneumatic and electropneumatic

control systems

EP-AL Electropneumatics for vocational training

KONST1 Energy-efficient design of systems – Part 1

KONST2 Energy-efficient design of systems – Part 2

Details of venues, dates and prices can be found in the current seminar planner.

Information regarding additional training media is available in our catalogues and on

the Internet. The Learning System for Automation and Technology is continually

updated and expanded. The sets of overhead transparencies, films, CD-ROMs and

DVDs as well as technical books are available in several languages.


The design of a compressed air network

The sizing of the pneumatic power section

The influence of tubing and connectors on the speed of travel

Reducing costs by means of different forward and return strokes

Reducing costs by means of preventing leakage

The operating behaviour of linear drives

The calculation of mass moments of inertia

The operating behaviour of semi-rotary drives

The function, actuation and selection of a Fluidic Muscle

Comparison between standard cylinders and the Fluidic Muscle

Evaluation of pneumatic control systems in the event of a power failure

Training aims of Advanced Level (TP 220)


Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Training aims

To be able to size compressed air

networks •

To familiarise yourself with the influence

of a network on the compressed air

medium

•

To be able to size a given pneumatic

control system with the help of diagrams • • •

To be able to size the connecting lines of

cylinders with the help of nomograms •


of connectors on the speed of travel of a

cylinder

•


of tubing lengths and diameters on the

speed of travel of a cylinder

•

To familiarise yourself with the savings

potential when operating a system using

different pressures for forward and return

strokes

•

To familiarise yourself with the effect of

leakage on the cost of a system •

To familiarise yourself with parameters

which influence the operating behaviour of

cylinders

•

To be able to take measures for

optimisation on the basis of the

application

•

To familiarise yourself with the difference

between air supply and exhaust air flow

control

•

Allocation of training aims and exercises

Allocation of training aims and exercises


Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Training aims

To familiarise yourself with different types

of end position cushioning •

To be able to select shock absorbers for an

application using a software tool •

To be able to calculate mass moments of

inertia of different bodies using a software

tool

•

To familiarise yourself with the

significance of the mass moment of inertia

when selecting semi-rotary drives

•

To familiarise yourself with parameters

which influence the operating behaviour of

semi-rotary drives

•

To familiarise yourself with the design and

function of the Fluidic Muscle •

To be able to name typical applications for

the Fluidic Muscle •

To be able to select a Fluidic Muscle for an

application with the help of a software tool •

To be able to assess the advantages and

disadvantages of Fluidic Muscles •

To be able to evaluate the behaviour of

pneumatic control systems in the event of

a power failure

•

To familiarise yourself with different

parameters for the EMERGENCY-STOP

situation

•

To be able to correctly use piloted non-

return valves in a control system •

To familiarise yourself with the effects of

faults in pneumatic control systems •


This equipment set for the advanced level has been compiled for further training in

electropneumatic control technology. The equipment sets (TP 201, TP 202 and

TP 220) contain all the components required to meet the specified training aims and

can be expanded as desired with other equipment sets of the Learning System for

Automation and Technology.

Description Order No. Quantity

3/2-way solenoid valve, normally closed, fast switching valve 544312 1

5/3-way solenoid valve, mid-position closed 541132 1

One-way flow control valve, 2 off 548634 2

Air reservoir 152912 1

On/off valve with filter regulator 152894 1

Function generator 544315 1

Loading weight, 0.175 kg 548581 2

Loading weight, 2 kg 548582 1

Small parts 544316 1

Plastic tubing 3 x 0.5, 5 m 197118 1

Plastic tubing 4 x 0.75, 10 m 151496 1

Plastic tubing 6 x 1. 5 m 152963 1

Linear drive 548641 1

Proximity sensor, electronic 548589 1

Fluidic Muscle 544311 1

Semi-rotary drive 544313 1

Equipment set - Advanced Level (TP 220)

Equipment set -

Advanced Level (TP 220

Order No.: 541184)



Overview of small parts (544316)

Description Order No. Quantity

Self-closing push-in fitting,

for tubing OD 6 mm

153420 1

Push-in T-connector,

for tubing OD 4 mm

153366 2

Push-in T-connector, reducing,

2 off for tubing OD 6 mm and

1 off for tubing OD 4 mm

153369 1

Push-in fitting,

for tubing OD 6 mm

153325 1

Push-in fitting with push-in sleeve, reducing,

Push-in sleeve OD 4 mm,

for tubing OD 3 mm

153328 4

L-Push-in fitting with push-in sleeve,

Push-in sleeve OD 4 mm,

for tubing OD 4 mm

153347 4

Push-in sleeve, reducing,

Push-in sleeve OD 6 mm and

push-in sleeve OD 4 mm

153257 1

Push-in sleeve,

Push-in sleeve OD 4 mm

153251 2



Description Symbol

3/2-way solenoid valve,

normally closed,

fast switching valve

2

1M131

1M1

5/3-way solenoid valve,

mid-position closed

24

35

14 12

1

1M1

1M1

1M2

1M2

One-way flow control valve,

2 off 1 2

Air reservoir

On/off valve with filter regulator

2

31

Function generator with counter

and stop watch

G

Equipment set symbols



Description Symbol

Weight m

Linear drive

Proximity sensor, electronic

Fluidic Muscle

Semi-rotary drive

Equipment set symbols

(continuation)


Note

Exercises 1 to 5, 7, 8, 10, 11 and 14 are theoretical exercises where software tools

are used in part to carry out calculations.

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Equipment

3/2-way solenoid valve, normally closed,

fast switching valve

1 1

5/3-way solenoid valve, mid-position

closed

1

One-way flow control valve, 2 off 1 2

Air reservoir 1 1

On/off valve with filter regulator 1 1 1 1 1 1

Function generator with counter and stop

watch

1 1 1 1

Loading weight, 0,175 kg 2

Loading weight, 2 kg 1

Linear drive 1 1 1

Proximity sensor, electronic 1

Fluidic Muscle 1 1

Semi-rotary drive 1

Allocation of equipment and exercises

Equipment set TP 220

Allocation of equipment and exercises


Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Equipment

2 x 3/2-way solenoid valve, normally

closed

1

5/2-way double solenoid valve 1 1 1 1

5/2-way solenoid valve 1

Double-acting cylinder 2 2 1

One-way flow control valve 2 2

Pressure sensor 1 1

Single-acting cylinder 1

On/off valve with filter regulator 1 1

Proximity sensor, electronic 2 2 2

Relay, 3-off 1 1 1 1 1 1

Signal input, electrical 1 1 1 1 1 1

Manifold 1 1 1 1 1 1

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Equipment

EMERGENCY-STOP pushbutton 1

Non-return valve, piloted 2

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Equipment

Pressure regulator with pressure gauge 1 1

Pressure gauge 2





Training aims

The general training aims of this collection of exercises are the sizing of the

pneumatic power section, the evaluation of the behaviour of pneumatic drives

and the safety of electropneumatic control systems in the event of a power

failure. The direct interaction of theory and practice ensures quick progress with

learning. The specific training aims are documented in the matrix. Specific,

individual training aims are allocated to each exercise definition.

Time required

The time required to work through the exercises depends on the prior knowledge

of the trainees. For trainees who are skilled manual workers in the engineering or

electrical engineering field: approx. 1 week. For trainees with technician’s or

engineering training: approx. 2 days.

Components of the equipment sets

The collection of exercises and the equipment set are harmonised. For exercises

6, 9, 12, 13, 15 and 16, you will need the components of the Advanced Level

equipment set TP 220. For additional components for the configuration of control

systems from equipment sets of Basic Level TP 101, Basic Level TP 201 and

Advanced Level, please refer to the equipment/exercise matrix. The above

exercises of the advanced level can be configured on a profile plate.

Theoretical exercises

Exercises 1 to 5, 7, 8, 10, 11 and 14 are theoretical exercises where software

tools are used in part to carry out calculations.

Methodological help for the trainer


All 16 exercises in Part A are of identical methodological structure.

The exercises are divided into:

Title

Training aims

Problem definition

Positional sketch

Work to be carried out

Worksheets

The proposed solutions in Part C are divided into:

Solution description

Circuit plan

Methodological structure of the exercise


The designation of components in the circuit diagrams is effected in accordance with

DIN-ISO 1219-2. All components of a circuit have the same main identification

number. Depending on the component, letters are assigned. If there are several

components within a circuit, these are numbered consecutively. The designation of

multiple pressure ports is P and these are consecutively numbered separately.

Drives: 1A1, 2A1, 2A2, ...

Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1, ...

Solenoid coils: 1M1, 1M2, 2M1, ...

Sensors: 1B1, 1B2, ...

Signal input: 1S1, 1S2, ...

Accessories: 0Z1, 0Z2, 1Z1, ...

Multiple pressure ports: P1, P2, ...

Designation of equipment


The CD-ROM supplied provides you with additional training media. The contents of

Parts A and C – exercises and solutions are stored in the form of pdf files.

The structure of the CD-ROM is as follows:

Operating instructions

Data sheets

Industrial applications

Software tools

Videos

Operating instructions and product information are available for the various devices

of the technology package. The purpose of these instructions is to assist you with

the use and commissioning of the devices.

The data sheets of the devices used in the technology package are available in the

form of pdf files.

Graphics of industrial applications are available whereby you can illustrate your own

exercise definitions. Similarly project presentations can also be supplemented with

the use of these illustrations.

The software tools required to work through the individual exercises are available on

the CD-ROM.

Note

Updates and additional software tools are available on the Internet at:

www.festo.com > Engineering > Selection & Sizing.

Videos of industrial applications complete the media for the technology package.

These demonstrate actual industrial applications in short sequences.

CD-ROM contents

Operating instructions

Data sheets

Industrial applications

Software tools

Videos


© Festo Didactic GmbH & Co. KG • 559880 A-1

Exercise 1:

Designing a compressed air network (theory) ______________________________ A-3

Exercise 2:

Sizing of the pneumatic power section (theory) ____________________________ A-9

Exercise 3:


the required stroke time (theory) _______________________________________ A-15

Exercise 4:


the required speed and given pressure (theory) ___________________________ A-23

Exercise 5:

Sizing of connecting lines for cylinders (theory) ___________________________ A-27

Exercise 6:

Analysing the speed of travel of linear drives (practical exercise) _____________ A-33

Exercise 7:


forward and return strokes (theory) _____________________________________ A-53

Exercise 8:

Reducing costs by means of preventing leakage (theory) ___________________ A-59

Exercise 9:

Analysing theoperating behaviour of linear drives (practical exercise) _________ A-63

Exercise 10:

Describing the end position cushioning of linear drives (theory) ______________ A-81

Exercise 11:

Calculating mass moments of inertia (theory) _____________________________ A-87

Exercise 12:

Analysing theoperating behaviour of semi-rotary drives (practical exercise) ____ A-93

Exercise 13:


the Fluidic Muscle (practical exercise) _________________________________ A-107

Exercise 14:

Selecting a Fluidic Muscle (theory) ___________________________________ A-119

Exercise 15:

Comparing standard cylinders and Fluidic Muscles (practical exercise) ______ A-123

Exercise 16:


a power failure (practical exercise) ___________________________________ A-133

Part A – Exercises

A-2 © Festo Didactic GmbH & Co. KG • 559880


Trainees

– are able to size compressed air networks

– are familiarised with the influence of the network design on

the compressed air medium

The purpose of an optimally designed compressed air network is to convey the

compressed air medium to consuming devices with a minimum of loss of air. This

means without reducing

• the quality (water, rust, dirt particles, etc.),

• the quantity of air (leakage) and

• the pressure (insufficiently sized).

The aim should therefore be to feed the compressed air, generated by the

compressor and subsequently prepared, to consuming devices under as little

changed conditions as possible. To ensure reliable and problem-free air distribution,

several points need to be taken into consideration, whereby the correct sizing of the

pipe system is equally important as the material, flow resistance, installation and

maintenance.

In the case of new installations, the future increase in air requirement should always

be taken into account. The size of the main line calculated on the basis of the current

requirement should therefore be increased accordingly. Blanking plugs and on/off

valves will enable problem-free expansion at a later stage.

Schematic representation of a compressed air network

Exercise 1:

Designing a compressed air network (theory)

Training aims

Problem definition

Positional sketch

Exercise 1: Designing a compressed air network (theory)


1. Determine the diameter of the pipe with the help of the nomogram.

2. Determine the equivalent lengths of resistances in the compressed air network.

3. Determine the total length of the compressed air network.

Work to be carried out



Exercise 1: Designing a compressed air network

Name: Date:

Assumed values of the compressed air network Sheet 1 of 4

Current requirement = 1000.0 m3/h

Planned increase = 50 % = 500.0 m3/h

Max. Permissible leakage = 10 % = 150.0 m3/h

Total requirement = 1650.0 m3/h

Operating pressure min. = 7 bar (700.0 kPa)

Permissible pressure drop Δp = 0.1 bar (10.0 kPa)

Extended length of main network = 400.0 m

The equivalent lengths of the following resistances need to be determined:

• Normal elbow pieces (90°) 30 off

• T-pieces 20 off

• Gate valves or ball valves 20 off

• Through-flow valves 5 off

Assumed values

Resistances in the main line




Name: Date :

Determing the pipe diameter Sheet 2 of 4

Step 1

– Determine the provisional diameter using the “determining the pipe diameter”

nomogram.

Information regarding the use of the “determining the pipe diameter” nomogram.

1. Draw a straight line from axis A (pipe length) to axis B (flow rate).

2. Extend the line until it intersects axis 1 (C).

3. Draw a second straight line from axis E (operating pressure) to axis G (pressure

loss). This results in an intersection at axis 2 (F).

4. A third straight line connects the intersections of axes 1 and 2. This third line cuts

axis D (inside pipe diameter).

Provisional diameter = ............ mm

Step 2

– Determine the equivalent lengths for the resistances using the “determining the

equivalent lengths” nomogram. Use the provisional diameter determined in

step 1 as the value for the diameter.

Normal elbow pieces (90°) 30 off @ ............ m = ............ m

T-pieces 20 off @ ............ m = ............ m

Gate valves or ball valves 20 off @ ............ m = ............ m

Through-flow valves 5 off @ ............ m = ............ m

Total equivalent length = ............ m

Total length = ............ m

Step 3

– Determine the definitive diameter using the “determining the pipe diameter”

nomogram.

Definitive diameter = ............ mm




Name: Date :

“Determining the pipe diameter” nomogram Sheet 3 of 4

5000

100

10

1.0

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0.05

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2015

1.5

0.7

0.4

0.2

0.15

0.07

0.03

0.04

0.3

7

3

2

40

70

150

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300

400

200

500

2000

5000

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200

100

50

20

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A B D FC E G

1000

100

4

5

10

20

50

100

25

15

20

30

10

Pressure loss[10 kPa (bar)]

2

Pipe length [m]

Flow rate [m /h]3

Inside pipediameter [mm] Axis 2

Axis 1

Operatingpressure

[10 kPa (bar)]2




Name: Date :

“Determining the equivalent lengths” nomograms Sheet 4 of 4

2015

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30 40 50 60 80 100 150 200 mm 400

1 1.5 2 3 4 5 7 8 9 10 12 Inches6

C

B

A

2

5

4

1

3

Nominal width

1: Through-flow valve, 2: Angle valve , 3: T-piece, 4: Gate valve, 5: Normal elbow piece

© Festo Didactic GmbH & Co. KG • 559880 C-1

Exercise 1:

Designing a compressed air network – solution ____________________________ C-3

Exercise 2:

Sizing of the pneumatic power section – solution ___________________________ C-7

Exercise 3:


the required stroke time – solution _____________________________________ C-11

Exercise 4:


the required speed and given pressure – solution _________________________ C-17

Exercise 5:

Sizing of connecting lines for cylinders – solution _________________________ C-19

Exercise 6:

Examining of speed of travel of linear drives – solution _____________________ C-23

Exercise 7:


forward and return strokes – solution ___________________________________ C-37

Exercise 8:

Reducing costs by means of leakage prevention – solution __________________ C-41

Exercise 9:

Analysing the operating behaviour of linear drives – solution ________________ C-43

Exercise 10:

Describing the end position cushioning of linear drives – solution ____________ C-55

Exercise 11:

Calculating mass moments of inertia – solution ___________________________ C-59

Exercise 12:

Analysing the operating behaviour of semi-rotary drives – solution ___________ C-63

Exercise 13:


the Fluidic Muscle – solution __________________________________________ C-71

Exercise 14:

Selecting a Fluidic Muscle – solution ____________________________________ C-77

Exercise 15:

Comparing standard cylinders and Fluidic Muscles – solution ________________ C-79

Exercise 16:


a power failure – solution _____________________________________________ C-83

Part C – Solutions

C-2 © Festo Didactic GmbH & Co. KG • 559880



Name: Date:

Assumed values of the compressed air network Sheet 1 of 4

Current requirement = 1000.0 m3/h

Planned increase = 50 % = 500.0 m3/h

Max. Permissible leakage = 10 % = 150.0 m3/h

Total requirement = 1650.0 m3/h

Operating pressure min. = 7 bar (700.0 kPa)

Permissible pressure drop Δp = 0.1 bar (10.0 kPa)

Extended length of main network = 400.0 m

The equivalent lengths of the following resistances need to be determined:

• Normal elbow pieces (90°) 30 off

• T-pieces 20 off

• Gate valves or ball valves 20 off

• Through-flow valves 5 off

Exercise 1:

Designing a compressed air network – solution

Assumed values

Resistances in the main line

Exercise 1: Designing a compressed air network – solution



Name: Date:

Determining the pipe diameter Sheet 2 of 4

Steps for the optimal configuration of the compressed air network

Step 1

– Determine the provisional diameter using the “determining the pipe diameter”

nomogram.

Provisional diameter = 120 mm

Step 2

– Determine the equivalent lengths for the resistances from the “determining the

equivalent lengths” nomogram. Use the provisional diameter determined in

step 1 as the value for the diameter.

Normal elbow pieces (90°) 30 off @ 1.6 m = 48.0 m

T-pieces 20 off @ 16.0 m = 320.0 m

Gate valves or ball valves 20 off @ 2.3 m = 46.0 m

Through-flow valves 5 off @ 49.0 m = 246.0 m

Total equivalent length = 660.0 m

Total length = 1060.0 m

Step 3

– Determine the definitive diameter using the “determining the pipe diameter”

nomogram.

Definitive diameter = 140 mm




Name: Date:

“Determining the pipe diameter” nomogram Sheet 3 of 4

5000

100

10

1.0

0.5

0.1

0.05

50

500

250

2015

1.5

0.7

0.4

0.2

0.15

0.07

0.03

0.04

0.3

7

3

2

40

70

150

200

300

400

200

500

2000

5000

10000

2000

1000

500

200

100

50

20

10

A B D FC E G

1000

100

4

5

10

20

50

100

25

15

20

30

10

Pressure loss[10 kPa (bar)]

2

Pipe length [m]

Flow rate [m /h]3

Inside pipediameter [mm] Axis 2

Axis 1

Operatingpressure

[10 kPa (bar)]2




Name: Date:

“Determining the equivalent lengths” nomogram Sheet 4 of 4

2015

0.2

0.3

0.4

0.5

0.6

0.8

1

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m

80

30 40 50 60 80 100 150 200 mm 400

1 1,5 2 3 4 5 7 8 9 10 126

C

B

A

2

5

4

1

3

Inches

Nominal width

1: Through-flow valve, 2: Angle valve, 3: T-piece, 4: Gate valve, 5: Normal elbow piece

Documents

CD-ROM included