Basic Level
Workbook
TP 601
CD-ROM included
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Festo Didactic
551150 EN
Order no.:
Date:
Author:
Graphics
Layout:
551150
05/2011
Renate Aheimer, Eberhard Bauer, Frank Ebel,
Christine Lffler, Dieter Merkle, Helmut Werner
Doris Schwarzenberger
09/2011, Beatrice Huber, Susanne Durz
Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2013
Internet: www.festo-didactic.com
E-mail: did@de.festo.com
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.
Table of contents
Use for intended purpose __________________________________________________________________ V
Preface _________________________________________________________________________________ VI
Introduction ____________________________________________________________________________ VIII
Work instructions and safety precautions _____________________________________________________ IX
Training package for electro-hydraulics, basic level (TP 601) ____________________________________ XI
Learning objectives, electro-hydraulics ______________________________________________________ XII
Allocation of learning objectives to exercises__________________________________________________ XIV
Equipment set _________________________________________________________________________ XVII
Allocation of components to exercises _______________________________________________________ XXI
Notes for the teacher/trainer______________________________________________________________ XXII
Structure of the exercises ________________________________________________________________ XXIII
Component designations _________________________________________________________________ XXIII
CD ROM contents _______________________________________________________________________ XXIV
III
IV
Preface
Festo Didactics training system for automation and technology is geared towards various educational
backgrounds and vocational requirements. Correspondingly, the training system is broken down as follows:
Technology oriented training packages
Mechatronics and factory automation
Process automation and control technology
Mobile robotics
Hybrid learning factories
The training system for automation and technology is continuously updated and expanded in accordance
with developments in the field of education, as well as actual professional practice.
The technology packages deal with various technologies including pneumatics, electro-pneumatics,
hydraulics, electro-hydraulics, proportional hydraulics, programmable logic controllers, sensor technology,
electrical engineering, electronics and electric drives.
The modular design of the training system allows for applications which go above and beyond the
limitations of the individual training packages. For example, PLC actuation of pneumatic, hydraulic and
electric drives is possible.
VI
VII
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 packages
TP 601 and TP 602 include electro-hydraulic controllers only.
The TP 601 basic level is suitable for fundamental training in the field of electro-hydraulic control
technology. On the basis of practically oriented problems, the workbook imparts knowledge regarding the
basic physical principles of electro-hydraulics, function and use of electro-hydraulic components and typical,
basic electrical circuits. Simple electro-hydraulic controllers can be set up with the equipment set. Basic
knowledge of hydraulic device technology is a prerequisite. The TP 602 advanced level is targeted at
vocational training in the field of electro-hydraulic control technology. More advanced electro-hydraulic
circuits can be set up with this equipment set.
Technical prerequisites for setting up the controllers include:
A Learnline or Learntop-S workstation equipped with a Festo Didactic slotted profile plate. The slotted
profile plate has 14 parallel T-slots at 50 mm intervals.
A hydraulic power unit (operating voltage: 230 V, 50 Hz, operating pressure: 6 MPa (60 bar),
volumetric flow: 2 l/min.)
A power pack with short-circuit protection (input: 230 V, 50 Hz, output: 24 V, max. 5 A)
Laboratory safety cables
Each of the circuits for all 15 exercises is set up using the TP 601 equipment set. The theoretical
fundamentals for understanding these exercises are included in the textbooks:
Hydraulics, basic level
Electro-hydraulics, basic level
Data sheets for the individual components are also available (cylinders, valves, sensors etc.).
VIII
General
Trainees should only work with the circuits under the supervision of a trainer.
Observe specifications included in the technical data 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 system
Only reach into the setup when it is at a complete standstill.
Mount all of the components securely onto the slotted profile plate.
Limit switches may not be actuated frontally.
Danger of injury during troubleshooting!
Use a tool to actuate the limit switches, for example a screwdriver.
Set all components up so that activation of switches and disconnectors is not made difficult.
Adhere to the instructions regarding positioning of the components.
Always set up cylinders together with the appropriate cover.
Electrical specifications
Use extra-low voltage only (max. 24 V DC).
Electrical connections may only be established in the absence of voltage.
Electrical connections may only be interrupted in the absence of voltage.
Only use connecting cables with safety plugs for electrical connections.
Pull the plug only when disconnecting connector cables never pull the cable.
Hydraulics
Limit system pressure to 6 MPa (60 bar).
Maximum permissible pressure for all devices included in the training package is 12 MPa (120 bar).
In the case of double-acting cylinders, pressure could be increased relative to surface area ratio due to
pressure boosting. With a surface area ratio of 1:1.7 and a system pressure of 6 MPa (60 bar), this may
result in a pressure value of greater than 10 MPa (100 bar).
All valves, devices and hose lines are equipped with self-sealing quick-release couplings.
IX
Mounting technology
The mounting boards for the components are equipped with mounting variant A, B or C:
Variant A, snap-in system
Lightweight devices which cannot be subjected to loads (e.g. directional control valves and sensors).
Simply clip the components into the slots on the slotted profile plate. Release the components from the
slots by actuating the blue lever.
Variant B, bolt system
Components with medium load capacity (e.g. hydraulic cylinders). These components are clamped to
the slotted profile plate with T-head bolts. The blue, knurled nut is used for clamping and loosening.
Variant C, screw system
For devices with high load capacity and devices which are seldom removed from the slotted profile plate
(e.g. the hydraulic power unit). These devices are fastened with socket head screws and T-head nuts.
Required accessories
A digital multimeter is required in order to ascertain the contact ratings of pushbuttons.
Current is measured with the digital multimeter.
Workbooks
DVD
Set of posters
Hydraulics
Simulation programme
FluidSIM Hydraulic
Training programmes including hydraulics, electro-hydraulics and electrical engineering 1 are available as
software for training package TP 601. These training programmes concern themselves in detail with the
basic principles of hydraulics, electro-hydraulics and electrical engineering. The GRAFCET training
programme provides a comprehensive introduction to the new GRAFCET standard. Training content is
elucidated on the basis of practical case studies in a systematic, applications-oriented fashion.
The media are offered in several languages. You will find further training materials in our catalogues and on
the Internet.
XI
Learning objectives
XII
Circuits
Be able to safely commission hydraulic controllers.
Be able to explain and set up direct actuation.
Be able to plan and set up load-dependent speed controllers.
Be able to make use of indirect actuation.
Be able to select and make use of hydraulic and electrical components in accordance with economic
considerations.
Become familiar with two ways of storing signals: with double solenoid valves and by means of
electrical self-latching loops.
Be able to explain and set up signal storage in the hydraulic power section.
Be able to select solenoid valves based on control technology requirements.
Be able to depict the motion sequence of a controller as a function diagram.
Be able to make use of a limit switch for end-position monitoring.
Become familiar with basic logic functions, and be able to make use of them and set them up.
Be able to create and make use of a sequence table.
Be able to plan and set up speed controllers which are independent of load.
Be able to explain and set up an electrical latching circuit with dominant breaking signal.
Become familiar with latching circuits with varying performance features.
Be able to plan and set up pressure dependent speed controllers.
Be able to plan and set up bypass circuits.
Be able to lock relay controller signals electrically and mechanically.
Be able to plan and set up circuits for pulling loads.
Be able to plan and set up a pressure level controller for two levels.
Become familiar with various types of end-position control for cylinders and be able to select the
appropriate type.
Be able to reduce a systems energy consumption by means of pressure-free pump circulation.
Become familiar with simple operating modes and be able to take them into consideration in the
controller.
Be able to expand existing controllers and revise the respective documentation accordingly.
Be able to implement sequence control with two cylinders.
Be able to represent a simple sequence in GRAFCET.
Be able to detect and eliminate errors in simple electro-hydraulic controllers.
Components
Become familiar with the setup and function of a hydraulic pump.
Become familiar with the most important characteristics of a hydraulic pump.
Be able to select a hydraulic power unit on the basis of specified requirements.
Be familiar with the various types and possible uses of pressure-relief valves.
Become familiar with the setup and function of a double-acting cylinder.
Become familiar with the setup and function of a 4/2-way solenoid valve.
Become familiar with the setup and function of electrical pushbuttons and switches.
Become familiar with the setup and function of a relay.
Become familiar with the setup and function of 2/2 and 3/2-way solenoid valves.
Become familiar with the setup and function of a 4/2-way double solenoid valve.
Become familiar with the setup and function of a limit switch.
Become familiar with the setup and function of an electronic pressure switch.
Become familiar with the setup and function of a 4/2-way double solenoid valve.
Measurements and calculations
Be able to measure and calculate electrical current in an electro-hydraulic system.
Become familiar with contact ratings of electrical signal generators and be able to take them into
consideration in the electrical circuit.
XIII
10
11
12
13
14
15
Learning objectives
Become familiar with the setup and function of a
hydraulic pump.
XIV
Exercise
10
11
12
13
14
15
Learning objectives
Become familiar with the setup and function of a
4/2-way double solenoid valve.
XV
Exercise
10
11
12
13
14
15
Learning objectives
Become familiar with the setup and function of
various 4/3-way solenoid valves.
Become familiar with various types of endposition control for cylinders and be able to
select the appropriate type.
XVI
Equipment set
The equipment set has been put together for basic training in the field of electro-hydraulic control
technology. It includes all of the components which are necessary for mastering the specified learning
objectives, and can be supplemented with any other equipment sets.
Order number
Quantity
544338
544346
544352
544347
On-off valve
152844
544371
572746
152843
Pressure-relief valve
544335
Pressure gauge
152841
548612
152972
183322
183345
548589
Relay, 3-off
162241
548618
162242
T-distributor
152847
159395
XVII
Graphic symbol
M1
M1
M1
M1
M2
M2
M1
M1
M2
M2
On-off valve
Double-acting cylinder,
16/10/200, with cover
XVIII
Component
Graphic symbol
Pressure-relief valve
Pressure gauge
EN 60617-7
ISO 1219-1
RD (1)
BK1 (4), SP1
BK2 (5), SP2
WH (2)
BU (3)
m
Electrical limit switch
1
Proximity switch, electronic
RD (1)
BK (4)
BU (3)
XIX
Component
Graphic symbol
Relay, 3-off
A1
12 14
22 24
32 34
42 44
11
21
31
41
12 14
22 24
32 34
42 44
A2
A1
A2
A1
11
21
31
41
12 14
22 24
32 34
42 44
11
21
31
41
A2
21
14
22
13
21
14
22
13
21
14
22
13
21
14
22
T-distributor
XX
10
11
12
13
14
15
Component
2-way flow control valve
1
1
Pressure-relief valve
Pressure gauge
1
1
T-distributor
1
1
1
1
10
11
12
13
14
15
Required accessories
Exercise
Component
Cover for weight
Digital multimeter
Hydraulic power unit
Power pack, 24 V DC
XXI
XXII
Solutions
The solutions specified in this workbook result from 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 for selected
professions on the subject matter of basic electro-hydraulic circuits.
Vocation
Topic
Mechatronics technician
Examination of the flow of energy and information in electrical, pneumatic and hydraulic assemblies
Implementing mechatronic subsystems
Industrial mechanic
Structure of exercises
All 15 exercises have the same methodological layout. The exercises are broken down into:
Title
Learning objectives
Problem description
Layout
Assignments
Work aids
Worksheets
The workbook includes the solutions for all of the worksheets for all 15 exercises.
Component designations
Components are designated in circuit diagrams in accordance with DIN ISO 1219-2. All of 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.
Cylinders:
Valves:
Sensors:
Signal input:
Accessories:
XXIII
CD-ROM contents
The workbook is included on the CD-ROM as a PDF file. The CD-ROM also provides you with additional
media.
The CD-ROM contains the following folders:
Operating instructions
Images
Data sheets
FluidSIM circuit diagrams
Presentations
Operating instructions
Operating instructions for various components in the training package are available. These instructions are
helpful with regard to component use and commissioning.
Images
Photos and graphics of components and industrial applications are made available. These can be used to
illustrate individual tasks. Project presentations can also be supplemented with these illustrations.
Data sheets
The data sheets for the components included in the training package are supplied along with the equipment
set, and are additionally available as PDF files.
FluidSIM circuit diagrams
The FluidSIM circuit diagrams for all 15 exercises included in the technology package are contained in this
directory.
Presentations
Short presentations for components included in the training package are included in this directory. They can
be used, for example, for the creation of project presentations.
XXIV
Exercise 1
Setting up a hydraulic workstation
Learning objectives
After completing this exercise:
You will be familiar with the setup and function of a hydro pump.
You will be familiar with the most important characteristics of a hydro pump.
You will be able to select a hydraulic power unit on the basis of specified requirements.
Problem description
A new hydraulic workstation needs to be set up in the training department. Size NG 4 products are used.
Maximum operating pressure is limited to 6 MPa (60 bar). A 230 V AC electrical outlet is available. A suitable
hydraulic power unit must be selected.
Layout
Hydraulic workstation
1.
2.
3.
4.
Assignments
Describe the setup and function of a hydro pump.
Calculate the volumetric flow rate of a hydro pump.
Calculate the efficiency of a hydro pump.
Select a hydraulic power unit on the basis of specified requirements.
Work aids
Data sheets
Hydraulics textbook
Control pump:
Displacement volume is controlled on the basis of pressure,
flow rate and power
The hydro pump generates volumetric flow (but no pressure). The delivery rate per revolution and the
drive speed dictate the pumps delivery rate which is specified in litres per minute.
Pressure only occurs as the result of resistance to pump delivery, for example flow resistance, load
resistance and pressure-relief valve settings. Pressure is specified in MPa or bar.
3
Cutaway view of a gear pump, 1: trapped fluid, 2: pressure chamber, 3: suction chamber
Gear pumps are constant-displacement pumps, because the displaced volume which is determined by
the gear tooth gap is unchangeable.
The gear pump functions on the basis of the following principle:
One gear wheel is connected to the drive unit, and the other rotates along with it via the toothing.
As a result of the volume enlargement which occurs when a tooth leaves a gear tooth gap, a
partial vacuum is generated in the suction chamber.
The hydraulic fluid fills the tooth chambers and is conveyed along the housing wall and into the
pressure chamber.
Here, the hydraulic fluid is displaced from the tooth chambers and into the hydraulic lines by the
teeth which then enter the tooth gaps.
Training notes
Trapped fluid is located in the tooth gaps between the suction chamber and the pressure chamber. This is
fed to the pressure chamber via a slot, because pressure peaks would otherwise occur due to
compression of the trapped oil which would result in noise and destruction of the pump.
Pump leakage oil quantities are determined by the size of the gap (between housing, tooth crests and the
sides of the teeth), overlapping of the gears, viscosity and speed.
b) Name the circuit symbol shown below and briefly describe the function of its components.
1
3
P
4
Circuit symbols for a hydraulic power unit
1.
2.
Hydraulic pump
Pump with constant delivery rate. The volumetric flow rate is dictated by motor speed and
displacement volume per revolution.
3.
Pressure gauge
Indicates prevailing pressure with a specified tolerance.
4.
Pressure-relief valve
Adjustable pressure-relief valve without oil return port. The valve begins to open when an
adjustable pressure level is reached.
c)
Match up the individual components of the hydraulic power unit with the corresponding numbers in the
drawing.
10
11
9
8
7
3
6
Component
Designation
Drain screw
Suction chamber
Suction tube
10
Moderating plate
Filling filter
11
Return
Return chamber
Given
Speed
Displacement volume
n = 1450 RPM
V = 2.8 cubic cm (per revolution)
Desired
Flow rate q in l/min.
Calculation
q = n V = 1450
1
cm3
dm3
l
3
= 4.06
= 4.06