EE052 Pneumatic Pr Inst

8/15/2019 EE052 Pneumatic Pr Inst

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SRI LANKA INSTITUTE OF ADVANCED TECHNOLOGICAL EDUCATION

Training Unit

Pneumatic

Practice

No: EE 052

ELECTRICAL and ELECTRONIC

ENGINEERING

Instructor Manual


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Training Unit

Pneumatic

Practical Part

No.: EE 052

Edition: 2008 Al l Rights Reserved

Editor: MCE Industrietechnik Linz GmbH & CoEducation and Training Systems, DM-1Lunzerstrasse 64 P.O.Box 36, A 4031 Linz / Austr iaTel. (+ 43 / 732) 6987 – 3475Fax (+ 43 / 732) 6980 – 4271Website: www.mcelinz.com


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PNEUMATIC

LIST OF CONTENT

CONTENTS Page

LEARNING OBJECTIVES ....................................................................................................4

Practical exercise 1: Single-acting cylinder controlled by 3/2-way valve ..............................5

Practical exercise 2: Single-acting cylinder controlled by a 3/2-way valve and pressure

control ...................................................................................................................................6

Practical exercise 3: Single-acting cylinder with throttled return stroke ................................7

Practical exercise 4: Single-acting cylinder with throttled advance and return stroke...........8

Practical exercise 5: Single-acting cylinder controlled from two separated switching points

(OR) ...................................................................................................................................... 9

Practical exercise 6: Single-acting cylinder controlled by a pneumatically actuated 3/2-way

valve....................................................................................................................................10

Practical exercise 7: Single-acting cylinder controlled from two separated switching points,actuated simultaneously (AND) ..........................................................................................12

Practical exercise 8: Double-acting cylinder controlled by a 5/2-way valve, manually

operated..............................................................................................................................13

Practical exercise 9: Double-acting cylinder controlled by a pneumatically actuated 5/2-way

valve with spring return .......................................................................................................14

Practical exercise 10: Double-acting cylinder controlled by a pneumatically actuated 5/2-

way valve and two manually operated 3/2-way valves. ......................................................15

Practical exercise 11: Bypass gate operated by a double-acting cylinder “Irrigating Plant”16


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Practical exercise 12: Transport device operated by a double-acting cylinder - “Singling out

from a Transport Device” ....................................................................................................18

Practical exercise 13. Double-acting cylinder with throttled air feed and throttled exhaust in

advanced and return stroke ................................................................................................20

Practical exercise 14: Double-acting cylinder controlled by a pneumatically actuated 5/2-

way valve with two separate switching points for the advance stroke ................................22

Practical exercise 15: Double-acting cylinder with pneumatically actuated 5/2-way valve

and immediate return stroke ...............................................................................................23


and time delayed return stroke ...........................................................................................24

Practical exercise 17: Coke silo is normally closed. Discharge chute is opened by push

button and remains open for 20 seconds “Coke Discharging Plant”...................................25

Practical exercise 18: Double- and single-acting cylinders by a 5/2-way controlled by a 5/2-

way valve. The forward strokes are effected simultaneously..............................................27


and automatic return stroke via 3/2-way roller lever valve.................................................. 28

Practical exercise 20: Arrange a pneumatics control system in accordance with a travel-

phase curve ........................................................................................................................29

Practical exercise 21: Double-acting cylinder with accelerated return stroke ..................... 30

Practical exercise 22: Double-acting cylinder with continuous advance and return stroke.31


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PNEUMATIC

LEARNING OBJECTIVES

The trainee should ...

be able to construct pneumatic control systems as per diagram supplied.

draw the system diagram for the control of a single acting cylinder with a 3/2-way valve

and construct it on the pneumatic stand.

draw and construct a system diagram of a single acting cylinder with throttled return

stroke.

draw the control system of a single-acting cylinder, controlled via two locally separated

switching points, actuated simultaneously with a 2-pressure valve and two 3/2-way

valve and construct this system on the pneumatic stand.

understand the application and function of a quick exhaust valve.

draw a pneumatic diagram of a double-acting cylinder with pressure dependent,

simultaneously effected return stroke and arrange it on the test hand.

draw the control system of a double-acting cylinder with automatic control sequence,

subject to travel and construct it on the pneumatic stand.


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Pneumatic

Practical exercise 1:

Single-acting cylinder controlled by 3/2-way valve

1. TASK

1. Draw the control system of a single-acting cylinder, controlled through a 3/2-way valve,

push-button actuated, with reversal by a return spring and arrange this system on a

pneumatic test stand.

2. Explain the function of this control system.

3. Draw a simplified sectional view of a single-acting cylinder.

4. Name the components of a single-acting cylinder.5. Complete the following sketch:

Note:

The drawing indicated below are to be used in answer 1 above.


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PNEUMATIC


Single-acting cylinder con trolled by a 3/2-way valve and pressure cont rol

1. TASK

1. Draw the control system of a single-acting cylinder with low operating pressure and

arrange this system on a pneumatic test stand.

2. Explain the application of a pressure regulator.

3. Complete the following sketch:

Note:

The drawings indicated below are to be used in answer 1 above.


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PNEUMATIC


Single-acting cylinder with throttled return stroke

1. TASK

1. Draw the control system of a single-acting cylinder with throttled piston speed during

the return stroke and arrange this system on a pneumatic test stand.

2. Draw the schematic sectional view of a throttle relief valve.


Note:


a)


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PNEUMATIC


Single-acting cylinder with th rottled advance and return stroke

1. TASK

1. Draw the control system of a single-acting cylinder with throttled piston speed during

the advance and return stroke and arrange this system on a pneumatic test stand.

2. The same as in 1 above with accelerated return stroke.

3. Explain the function of a quick exhaust valve.

4. Complete the following sketches:

Note:


1) 2)


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PNEUMATIC


Single-acting cylinder control led from two separated switching points (OR)

1. TASK

1. Draw the control system of a single-acting cylinder, controlled from two separated

switching points (using a shuttle valve) and arrange this system on a pneumatics test

stand.

2. Explain the function of a shuttle valve referring to task 1.


Note:


1)


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PNEUMATIC


Single-acting cylinder controlled by a pneumatically actuated 3/2-way valve

1. TASK

1. Draw the control system of a single-acting cylinder with a pneumatically controlled 3/2-

way valve. Arrange this system on a pneumatic test stand.

2. Draw the control system of a single-acting cylinder with two locally separated switching

points and pneumatically controlled 3/2-way valve and arrange this on the test stand.

3. The same as in 2 above, with throttled advance stroke.

4. The same as in 2 above, with throttled return stroke.5. Complete the following sketches:

Note:

The drawings indicated below are to be used in answer 1, 2, 3, and 4 above.

1) 2)


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3)

4)


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PNEUMATIC


Single-acting cylinder controlled from two separated switching points, actuated

simul taneously (AND)

1. TASK

1. Draw the control system of a single-acting cylinder, controlled via two locally separated

switching points, actuated simultaneously (interlocked control through a two pressure

valve) and two 3/2-way valves and arrange this on a pneumatic test stand.

2. Explain the function of an AND-valve.3. Complete the following sketch:

Note:


1)


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PNEUMATIC


Double-acting cylinder controlled by a 5/2-way valve, manually operated

1. TASK

1. Draw the control system of a double-acting cylinder with a 5/2-way valve, push-button

actuated, with reversal by a return spring and arrange this on a pneumatic test stand.

Install an optical indicator in the working connection B.


3. Draw a schematic sectional view of a double-acting cylinder.4. Name the components which are different for single-acting and double-acting cylinders.

5. Complete the following sketch.

Note:


1)


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PNEUMATIC


Double-acting cylinder con trolled by a pneumatically actuated 5/2-way valve with

spring return

1. TASK

1. Draw the control system of a double-acting cylinder with pneumatically actuated 5/2-

way valve, with reversal by return spring. Arrange this on a pneumatic test stand.

2. Mark all units of the control system with successive numbers.


Note:


1) 2)


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PNEUMATIC


Double-acting cylinder con trolled by a pneumatically actuated 5/2-way valve and two

manually operated 3/2-way valves.

1. TASK

1. Draw the control system of a double-acting cylinder with pneumatically actuated 5/2

impulse valve and arrange this on a pneumatic test stand.

2. Mark all units of the control system with successive numbers.


Note:

The drawings indicated below are to be used in answer 1 and 2 above.

1) 2)


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PNEUMATIC


Bypass gate operated by a double-acting cylinder “ Irrigating Plant”

Problem:

... In an irrigating plant a switch is to be operated in such a way that the water flow can be

directed or bypassed according to which button is pushed.

1. TASK

1. Design the circuit diagram according to DIN 24300 and arrange the control system on a


2. Illustrate and explain the function of the impulse valve to be built-in.

3. Mark the control system with successive numbers.


supply of water

flow channel 2

flow channel 1


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Note:


1) 3)


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PNEUMATIC


Transport device operated by a double-acting cylinder - “Singli ng out from a

Transport Device”

Problem:

At a collecting bin, packets are to be singled. The slide has to push the packet on to the

loading road. When a packet has been moved, the slide has to bear the load of the

remaining packets until it returns to the starting position. The cycle of operations is to be

started by a push button.

1.

TASK

1. Design the circuit diagram according to DIN 24300 and arrange the control system on a


2. Illustrate and explain how the signal input unit depends on the position.

3. Explain the application of a 5/2-way valve and of the double-acting cylinder.

4. Mark the circuit diagram with successive numbers.



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Note:


1) 2)


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PNEUMATIC

Practical exercise 13.

Double-acting cyl inder with thrott led air feed and thrott led exhaust in advanced and

return stroke

1. TASK

1. Draw the control system of a double-acting cylinder with selector switch actuated 5/2-

way valve, reversal by return spring, advance stroke with throttled compressed air feed,

return stroke with throttled exhaust air and arrange this on a pneumatic test stand.

Install an optical indicator in working connection B.

2. The same as in 1 above but with throttled exhaust air on advance stroke and throttledcompressed air feed on return stroke.

3. The same as in 1 but with throttled compressed air feed on both advance and return

strokes.

4. The same as in 1 but with throttled exhaust air on advance and return strokes.

5. Mark all elements with successive numbers.


Note:

The drawings indicated on the following page are to be used in answers 1, 2, 3, and 4

above.


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1) 2)

3) 4)


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PNEUMATIC


Double-acting cylinder con trolled by a pneumatically actuated 5/2-way valve with

two separate switching points for the advance stroke

1. TASK

1. Draw the control system of a double-acting cylinder with pneumatically actuated 5/2-

way valve. The control of the advance stroke is from either of two separate switching

points. Arrange this control system on a pneumatic test stand.



Note:


1) 2)


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PNEUMATIC


Double-acting cylinder with pneumatically actuated 5/2-way valve and immediate

return stroke

1. TASK

1. Draw a control system of a double-acting cylinder with pneumatically actuated 5/2-way

valve. The return stroke is immediately effected by a pressure sequence valve.


3. Explain the control system.


Note:



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PNEUMATIC


Double-acting cylinder with pneumatically actuated 5/2-way valve and time delayed

return stroke

Problem:

A cylinder should be moved out by operation of a push-button and returned after a pre-set

time

1. TASK

1. Design the circuit diagram according to DIN 24300 and arrange this control system ona pneumatic test stand.

2. Illustrate and explain the application of a time delay valve in order to hold the moved-

out position of the cylinder for a period after the advance stroke (with normal return

stroke).


Note:

The drawings indicated below are to be used in answer 1 below.

1)


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PNEUMATIC


Coke silo is normally closed. Discharge chute is opened by push button and

remains open for 20 seconds “ Coke Discharging Plant”

Problem:

The coke silo normally closed. The discharged chute is opened by push-button actuation,

remains open for 20 sec. and is automatically closed.

1. TASK

1. Design the circuit diagram according to DIN 24300 and arrange this control system on

a pneumatic test stand.

2. Explain the control sequence.


Note:

The drawings indicated below are to used in answer 1 above.


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1)


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PNEUMATIC


Double- and single-acting cylinders by a 5/2-way controlled by a 5/2-way valve.

The forward strokes are effected simultaneously.

1. TASK

1. Draw the control system of a double acting cylinder in such a way that, when moving

out, a single-acting cylinder is controlled at the same time.


3. Draw a travel-phase and a valve-phase curve.


Note:


2)


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PNEUMATIC


Double-acting cylinder with pneumatically actuated 5/2-way valve and automatic

return stroke via 3/2-way roller lever valve

1. TASK

1. Draw the control system of a double acting cylinder with automatic return, effected by

cam operation of a 3/2-way valve. Arrange this on a pneumatic test stand.


3. Draw the travel-phase and the valve-phase curves for this control system.


Note:


2)


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PNEUMATIC


Arrange a pneumatics control system in accordance wi th a travel-phase curve

1. TASK

Read the travel-phase, travel-time and valve-phase curves which are represented below.

Draw the corresponding OR-control system and arrange this system on a pneumatic test

stand.

Phases

1.0 cylinder

1.1 valve

1.2 push button valve

1.4 push button valve

Phases

1.0 cylinder

Duration in sec.


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PNEUMATIC


Double-acting cy linder with accelerated return s troke

1. TASK

1. Draw the control system of a double-acting cylinder with accelerated return stroke and

arrange this on a pneumatic test stand. Install an optical indicator in working

connection B.


3. Design the travel-phase and the travel-time curves of this control system.


Note:

The drawings indicated below are to be use d in answer 1 and 2 above.

2)


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PNEUMATIC


Double-acting cyl inder with continuous advance and return stroke

1. TASK

1. Draw the control system of a double-acting cylinder with automatic, travel controlled,

sequences and arrange this on a pneumatic test stand. The control sequence is

repeated continuously; it starts when compressed air is applied and stops when

compressed air is no longer applied. Install a pressure regulator before your control

system.

2. Explain the function of this control system.3. Complete the following sketch:

Note:


1)


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Pneumatic

Instructions for Practical Exercises


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PNEUMATIC

INSTRUCTION for practical exercise 1

Single-acting cylinder controlled by 3/2-way valve

1. SOLUTION

1.

2. In its starting position the 3/2-way valve stops the compressed air feed, the cylinder

remains in its moved-in position. By pushing the button the valve is switched over, the

compressed air flows through the valve and effects the advance stroke (working

stroke). The cylinder remains in this moved-out position as long as the button is

pushed. With releasing the button the valve stops the feed of compressed air and the

piston returns in its initial position by the spring force (no working stroke).

3.

4. Cylinder barrel with caps, piston, piston rod, return spring, compressed air connection,

air relief, packing, scraping ring.


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PNEUMATIC


Single-acting cylinder controlled by a 3/2-way valve and pressure control

1. SOLUTION

1.

2. The pressure regulator with automatic exhaust is used to set the operating pressure of

a cylinder or pneumatic control systems.


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PNEUMATIC


Single-acting cylinder with throttled return stroke

1. SOLUTION

1.

2.


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PNEUMATIC


Single-acting cylinder with throttled advance and return stroke

1. SOLUTION

1.


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2.

3. The quick exhaust valve is applied for increasing the piston speed. The air displaced by

the piston need not be blown via pipelines through and exhaust air relief but is

immediately released through the quick exhaust valve arranged next to the cylinder.


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PNEUMATIC


Single-acting cylinder controlled from two separated switching points (OR)

1. SOLUTION

1.

2. The shuttle valve connects two locally separated switching points (3/2-way valves).

Thus, the cylinder can be controlled from each of the two switching points. In case one

of the two valves is switched over by pushing the button, compressed air flows to the

cylinder via shuttle valve. The shuttle valve closes the pipeline which is out of

operation, thus the system cannot be vented via the second, closed valve.


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PNEUMATIC


Single-acting cylinder controlled by a pneumatically actuated 3/2-way valve

1. SOLUTION

1.


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2.


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3.

4.


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PNEUMATIC


Single-acting cylinder controlled via two locally separated switching points, actuated

simultaneously (AND)

1. SOLUTION

1.

2. If one of the two compressed air connections is under pressure, the valve is closed.

Compressed air flows to the working connection but not before the other compressed

air connection is under pressure.


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PNEUMATIC


Double-acting cylinder controlled by a 5/2-way valve, manually operated

1. SOLUTION

1.

2. In the starting position of the 5/2-way valve, compressed air flows to the cylinder via the

working connection B, the piston remains in its starting position. By pushing the button

the valve is switched over, compressed air flows through the connection A and effects

the advance stroke (A= working stroke). Connection B is vented. The piston remains in

this position as long as the button is pushed. When the button is released, the valve is

switched back. Compressed air flows into cylinder via connection B and effects the

return stroke (working stroke). Connection A is vented.


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3.

4. Sealing:

Single or double packing.

Return spring.

Air exhaust hole or working connection.


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PNEUMATIC


Double-acting cylinder controlled by a pneumatically actuated 5/2-way valve with spring

return

1. SOLUTION

1. 2.


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PNEUMATIC


Double-acting cylinder controlled by pneumatically actuated 5/2-way valve and two

manually operated 3/2-way valves

1. SOLUTION

1. 2.


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PNEUMATIC


Bypass gate operated by a double-acting cylinder

1. SOLUTION

1. 3.

2. The impulse valve applied is a 5/2-way valve which stores all impulses received until a

counter impulse arrives at the valve.


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PNEUMATIC


Transport device operated by a double-acting cylinder

1. SOLUTION

1. 4.

2. The 3/2-way valve 1.3 actuated as soon as the piston of the cylinder 1.0 has been

completely moved out and the packet has reached the loading rack. The piston thus

returns to its starting position.

3. The double-acting cylinder is necessary as a load (pressure of the following packets)has to be borne during both the advance and return stroke. The double-acting cylinder

requires a 5/2-way valve for its control.


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PNEUMATIC


Double-acting cylinder with throttled air feed and throttled exhaust in advance and return

stroke

1. SOLUTION

1. 1.


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2.


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3.


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4.


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PNEUMATIC


Double-acting cylinder controlled by a pneumatically actuated 5/2-way valve with two

separate switching points for the advance stroke

1. SOLUTION

1. 2.


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PNEUMATIC


Double-acting cylinder with pneumatically actuated 5/2-way valve and immediate return

stroke

1. SOLUTION

1. 2.

3. The 5/2-way valve 1.1 is actuated by the 3/2-way valve 1.2 the piston is moving out.

The return stroke is pressure dependant. If the piston is held up during the forward

stroke or at it’s final position the pressure on the piston side builds up and the pressuresequence valve 1.3 is actuated. The 5/2-way valve 1.1 is switched to it’s initial position.


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PNEUMATIC


Double-acting cylinder with pneumatically actuated 5/2-way valve and time delayed return

stroke

1. SOLUTION

1.

2. After normally executed advance stroke of the double-acting cylinder compressed air

flows slowly via a time delay valve (consisting of a throttle relief valve with reservoir

and 3/2-way valve), which effects the delay. The duration of the delay can be adjustedat the throttle. The 3/2-way valve is switched over when sufficient pressure has been

reached.

The 5/2-way valve is switched into its starting position by the out-going impulse. The

piston then returns to it’s starting position with a normal stroke.


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PNEUMATIC


Coke silo is normally closed. Discharge chute is opened by push-button and remains open

20 second

1. SOLUTION

1.

2. The piston, in the starting position, is moved out and blocks the discharging chute.

On pushing the button (1.2) the 5/2-way valve (1.1) is switched over, the piston movesin and opens the discharge chute. The coke is now thrown on to the wagon and the

moved-in piston switches over the valve (1.3). This gives an impulse to the time delay

valve (1.5). The time delay valve responds with a delay of approx. 20 sec., the control

unit (1.1) is switched, the piston moves out and the discharging chute is closed again.


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PNEUMATIC


Double-and single-acting cylinders are controlled by a 5/2-way valve.

The forward strokes are effected simultaneously

1. SOLUTION

1. 2.


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3.

Phase


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PNEUMATIC


Double-acting cylinder with pneumatically actuated 5/2-way valve and automatic return

stroke via 3/2-way roller lever valve

1. SOLUTION

1. 2.


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3.

Phase


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PNEUMATIC


Arrange a pneumatic control system in accordance with a travel-phase curve

1. SOLUTION

1.


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PNEUMATIC


Double-acting cylinder with accelerated return stroke

1. SOLUTION

1. 2.


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3.

Travel-phase curve

Travel-time curve

Duration in sec.


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PNEUMATIC


Double-acting cylinder with continuous advance and return stroke

1. SOLUTION

1.


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2. As soon as compressed air is applied, the valves 1.2 and 1.3 are alternately operated

as the piston reaches its moved-in or moved-out position. These signal units alternately

give impulses to the regulating unit 1.1; the piston is continuously moved in and moved

out. The control sequences are finished when the compressed air is stopped.


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Pneumatic

Evaluation Sheet for Practical Exercises


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EVALUATION SHEET

Name Control No. Group

Total

S h e e t N o . Circuit

diagram

(drawing)

P o s s i b l e p o i n t s

A c t u a l p o i n t s

Construct

ion


A c t u a l p o i n t s Description

of function

(reason)



General

neatness





1 a)

b)

3

2

5 5 5

20

2 4 4 4 3 15

3 a)

b)

3

2

5 5

15

4 a)

b)

5

5

a)

b)

5

5

5 5

30

5 5 5 5 5 20

6 a)

b)

c)

d)

4

4

2

2

a)

b)

c)

d)

4

4

2

2

6

30

Total:41 4

1

19 29 130

Intermediate Mark: Date: Points:


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EVALUATION SHEET


Total


diagram

(drawing)



Construct

ion



of function

(reason)



General

neatness





7 5 a)

b)

5

3

3 4

20

8 a)

b)

4

2

4 3 2

15

9 4 4 2 10

1

0

4 4 2 10

1

1

4 4 2 10

1

2

4 4 b)

c)

4

4

4

20

1

3

a)

b)

c)

d)

4

2

2

2

a)

b)

c)

d)

4

2

2

2

5

25

Total :37 3

8

14 21 110



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EVALUATION SHEET


Total


diagram

(drawing)



Construct

ion



of function

(reason)



General

neatness





14 4 4 2 10

15 4 4 5 2 15

16 5 5 5 5 20

17 5 5 5 5 20

18 a)

c)

5

5

5 5

20

19 a)

c)

5

5

5 5

20

20 5 5 5 15

21 a)

c)

4

4

4 3

15

22 a)

b)

4

4

4

3

15

Total :

59 4

1

15 35 150



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EE 052

Pneumatic

Practical Test


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PNEUMATIC

PRACTICAL TEST

1. Draw the control system of a double-acting cylinder with automatic control sequence,

delayed return stroke and arrange this on a pneumatic test stand.



Note:


1. 2.



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PNEUMATIC

PRACTICAL TEST

(Solution)

1. 2.

3. Valve 1.2 is operated by push button. The impulse switches over the regulating unit 1.1

and the piston moves out.

According to the pre-set time delay valve 1.3 actuates the regulating unit 1.1 and the

piston returns to its starting position.

The sequence is then finished.


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PNEUMATIC

EVALUATION SHEET FOR PRACTICAL TEST

Points

1. Control system correctly draw 10

2. Construction of control system 10

3. Serial numbers 5

4. Description of function 10

5. Overall neatness 5

POSSIBLE POINTS 40

ACTUAL POINTS


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KEY TO EVALUATION

PER CENT MARK

88 – 100 1

75 – 87 2

62 – 74 3

50 – 61 4

0 – 49 5

Documents

EE052 Pneumatic Pr Inst