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Learning System for Automation and Communications Hydraulics Workbook Basic Level 094468 Authorised applications and liability The Learning System for Automation and Communication has been developed and prepared exclusively for training in the field of automation and communication. The training organization and / or trainee shall ensure that the safety precautions described in the accompanying Technical documentation are fully observed. Festo Didactic hereby excludes any liability for injury to trainees, to the training organization and / or to third parties occurring as a result of the use or application of the station outside of a pure training situation, unless caused by premeditation or gross negligence on the part of Festo Didactic. Order no.: Description: Designation: Edition: Layout: Graphics: Author: 094468 TEACHW. HYDRAUL. D.S501-C-SIBU-GB 11/1998 03.11.1998, OCKER Ingenieurbüro OCKER Ingenieurbüro D. Waller, H. Werner © Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 1998 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 registrations. Parts of this training documentation may be duplicated, solely for training purposes, by persons authorised in this sense. TP501 • Festo Didactic 3 Preface Festo Didactic’s Learning System for Automation and Communications is designed to meet a number of different training and vocational requirements. The Festo Training Packages are structured accordingly: „ Basic Packages provide fundamental knowledge on a wide range of technologies. „ Technology Packages deal with important areas of open-loop and closed-loop control technology. „ Function Packages explain the basic functions of automation systems. „ Application Packages provide basic and further training closely oriented to everyday industrial practice. Technology Packages deal with the technologies of pneumatics, electropneumatics, programmable logic controllers, automation with PCs, hydraulics, electrohydraulics, proportional hydraulics and application technology (handling). Fig. 1: Hydraulics 2000 – i.e. mobile workstation Mounting frame U = 230V~ Profile plate p = 6 MPa Storage tray TP501 • Festo Didactic 4 The modular structure of the Learning System permits applications to be assembled which go beyond the scope of the individual packages. It is possible, for example, to use PLCs to control pneumatic, hydraulic and electrical actuators. All training packages have an identical structure: „ „ „ „ Hardware Courseware Software Courses The hardware consists of industrial components and installations, adapted for didactic purposes. The courseware is matched methodologically and didactically to the training hardware. The courseware comprises: „ Textbooks (with exercises and examples) „ Workbooks (with practical exercises, explanatory notes, solutions and data sheets) „ OHP transparencies and videos (to bring teaching to life) Teaching and learning media are available in several languages. They have been designed for use in classroom teaching but can also be used for self-study purposes. In the software field, computer-based training programs and programming software for programmable logic controllers are available. Festo Didactic’s range of products for basic and further training is completed by a comprehensive selection of courses matched to the contents of the technology packages. TP501 • Festo Didactic 5 Latest information about the technology package TP501. New in Hydraulic 2000: „ Industrial components on the profile plate. „ Exercises with exercise sheets and solutions, leading questions. „ Fostering of key qualifications: Technical competence, personal competence and social competence form professional competence. „ Training of team skills, willingness to co-operate, willingness to learn, independence and organisational skills. Aim – Professional competence Content Part A Course Exercises Part B Fundamentals Reference to the text book Part C Solutions Function diagrams, circuits, descriptions of solutions and quipment lists Part D Appendix Storage tray, mounting technology and datasheets TP501 • Festo Didactic 6 TP501 • Festo Didactic 7 Table of contents Introduction 11 Notes on safety 13 Notes on operation 13 Technical notes 14 Training contents 17 Equipment set for “Hydraulics Basic Level” 19 Component / exercise table for TP 501 24 Section A – Course Exercise 1: Automatic lathe Pump characteristic A-3 Exercise 2: Package lifting device Pressure relief valve characteristic A-7 Exercise 3: Drawing press Hydraulic resistances A-11 Exercise 4: Calender feeding device Single-acting cylinder (basic circuit) A-15 Exercise 5: Hardening furnace Single-acting cylinder (measurement and calculation) A-19 Exercise 6: Furnace door control Double-acting cylinder A-23 Exercise 7: Conveyor tensioning device 4/3-way valve with bypass to pump A-29 Exercise 8: Cold-store door Accumulator A-33 Exercise 9: Rotary machining station Flow control valve and counter-holding A-37 Exercise 10: Painting booth Flow control valve characteristic A-41 TP501 • Festo Didactic 8 Exercise 11: Embossing machine One-way flow control valve and counter-holding A-45 Exercise 12: Surface grinding machine Differential circuit A-49 Exercise 13: Drilling machine Pressure regulator A-55 Exercise 14: Bulkhead door Hydraulic clamping of a cylinder A-59 Exercise 15: Ferry loading ramp Flow control valve in inlet and outlet lines A-63 Exercise 16: Skip handling Varying load A-69 Exercise 17: Bonding press Comparison of pressure regulator and – pressure relief valve A-73 Exercise 18: Assembly device Pressure sequence circuit, displacement-step diagram A-77 Exercise 19: Assembly device Calculation of pressure and time A-81 Exercise 20: Tipping container Electrohydraulics A-85 Section B - Fundamentals TP501 • Festo Didactic 9 Section C – Solutions Solution 1: Automatic lathe C-3 Solution 2: Package lifting device C-7 Solution 3: Drawing press C-11 Solution 4: Calender feeding device C-15 Solution 5: Hardening furnace C-19 Solution 6: Furnace door control C-23 Solution 7: Conveyor tensioning device C-27 Solution 8: Cold-store door C-33 Solution 9: Rotary machining station C-37 Solution 10: Painting booth C-41 Solution 11: Embossing machine C-45 Solution 12: Surface grinding machine C-49 Solution 13: Drilling machine C-59 Solution 14: Bulkhead door C-65 Solution 15: Ferry loading ramp C-69 Solution 16: Skip handling C-73 Solution 17: Bonding press C-77 Solution 18: Assembly device C-79 Solution 19: Calculation for an assembly device C-83 Solution 20: Tipping container C-85 Section D – Appendix Storage tray D-3 Mounting systems D-4 Sub-base D-6 Coupling system D-7 Data sheets TP501 • Festo Didactic ... 10 TP501 • Festo Didactic