Festo-Proportional Hydraulics Advanced Level

Learning System for Automation
Proportionalhydraulics
Workbook Advanced Level
094473
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:
094473
TEACHW. P-HYDR.
D.S702-C-SIBU-GB
08/1999
06.08.1999, OCKER Ingenieurbro
D. Schwarzenberger
E. Bauer
Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 1999

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.
TP702 Festo Didactic
Preface
The Festo Didactic Learning System for Automation and Communications is designed to meet a number of different training and vocational
needs. The Training packages are structured accordingly:
Basic packages deal with basic knowledge spanning a wide range of

technologies.
Technology packages deal with important areas of control technology.
Function packages explain the basic functions of automation systems.
Application packages provide basic and further training loosely oriented to everyday industrial practice.
The technology packages deal with the following technologies: Pneumatics, electro-pneumatics, programmable logic controllers, automation
using a personal computer, hydraulics, electro-hydraulics, proportional
hydraulics and handling technology.
Fig. 1:
Example of
Hydraulics 2000
Mobile laboratory trolley
Mounting frame
U = 230V~
Profile plate
p = 6 MPa
Storage tray
The modular design of the learning system permits applications which

go beyond the scope of the individual packages, such as PLC actuation
of pneumatic, hydraulic and electrical actuators.
All learning packages are of an identical structure:
Hardware
Teachware
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 and comprises:
Textbooks (with exercises and examples)

Workbooks (with practical exercises, supplementary notes, solutions
and data sheets)
Overhead transparencies and videos (to provide a lively, interactive

classroom atmosphere)
Teaching and training media are available in several languages. They
have been designed for use in classroom teaching, but can also be used
for self-tuition purposes.
As far as software is concerned, computer-based training programs and
programming software for programmable logic controllers are available.
Festo Didactics range of products for basic and further training is completed by a comprehensive selection of courses matched to the contents
of the technology packages.
Information on the
Technology Package Proportionalhydraulics TP702
New features of Hydraulics 2000
All electrical cables with safety plugs.

Authentic industrial components, nominal size 4 mm, on the profile
plate.
Exercises with exercise sheets and solutions, leading questions.

Development of key qualifications:
Technical competence, methodological competence, social competence and personal competence.
Practice in teamwork, cooperation, study technique, independence

and organisational ability.
Objective Competence in action
Contents
Section A Course
Exercises and worksheets
Section B Fundamentals
Refer to textbook
Section C Solutions
Function diagram, circuit diagrams, solution description and components lists
Section D Appendix
Storage tray, mounting systems, coupling

system and data sheets
Table of contents
Introduction
Safety recommendations
11
Notes on procedure
11
Technical notes
12
Notes on procedure regarding proportional hydraulics
13
Training contents of Proportional Hydraulics Advanced Level TP702 22

List of training aims of the exercises
23
Equipment set Proportional hydraulics Basic level TP701
24
Equipment set Proportional hydraulics Adavanced level TP702
25
Allocation of components and exercises
29
Methodical structure of the exercises
30
Section A Course
Exercise 1:
Exercise 2:
Exercise 3:
Exercise 4:
Exercise 5:
Exercise 6:
Exercise 7:
Pressure sensor
Characteristic line, binary and analogue signal
A-3
Temperature sensor
Temperature monitoring control
A-9
Displacement sensor
Sensor characteristics,
basic control using displacement sensors
A-15
Curing press
Accelerating, decelerating, velocity stages
A-25
Hydraulic lift
Interrupt positioning
A-33
Drawing press
Drive acceleration by means of
Proportional pressure relief valve
A-41
Honing machine
Oscillation of hydraulic drives
A-49
Exercise 8:
Mould closing device

bypass circuit, Soft stop
A-57
Exercise 9:
Injection moulding machine

Simulation of complex injection moulding processes A-65
Exercise 10:
Injection moulding machine with mould

closing device
Overall process, Proportional flow control valves
A-73
Section C Solutions
Solution 1:
Pressure sensor
C-3
Solution 2:
Temperature sensor
C-13
Solution 3:
Displacement sensor
C-17
Solution 4:
Squeezing press
C-25
Solution 5:
Hydraulic lift
C-35
Solution 6:
Drawing press
C-49
Solution 7:
Honing machine
C-55
Solution 8:
C-63
Solution 9:
C-71
Solution 10:
Injection moulding machine with

mould closing device
C-79
Section D Appendix
Assembly technology
D-3
Sub-base
D-5
Coupling technology
D-6
Data sheets
...
Introduction
This workbook forms part of Festo Didactics Learning System for
Automation and Communication. TP700 is intended as an introduction
to the fundamentals of proportional hydraulics and consists of a basic
level and advanced level. The basic level TP701 provides the basic
knowledge on proportional hydraulics, which is consolidated and dealt
with in greater depth in the advanced level TP702.
The following points have been included in the design concept of the
hydraulic components:
Simple handling
Secure attachment
Environmentally friendly coupling technology
Compact components
Practice-oriented measuring technology
The following are recommended for the practical implementation of the

exercises:
Hydraulic and electrical components of equipment sets TP701 and

TP702
A hydraulic power pack

Several hoses
A power supply unit
A set of cables
A slotted profile plate or corresponding laboratory equipment
The measuring set with the necessary sensors
10
The aim of this workbook is to familiarise the student with the equipment
and basic circuits of proportional hydraulics. The exercises deal with the
following subjects:
Plotting of characteristic curves of various sensors.

Use of equipment, valves and sensors.
Construction of different circuits according to specified flow diagrams.
Optimum harmonisation of components by means of setting parameters.
The technical prerequisites for the safe operation of components are:
A hydraulic power pack for an operating pressure of 60 bar and

volumetric flow rate of 2 l/min.
A voltage supply of 230 V AC for the power pack.

A power supply unit with 24 V D.C. for the electrical components.
A Festo Didactic slotted profile plate for the attachment of components.
This workbook has been developed for use in the Dual system of vocational training. It is, however, equally suitable for use in providing a
practical introduction to electrohydraulics for students at universities and
technical colleges. The modular design of the hardware allows theoretical questions to be dealt with experimentally in a simple and efficient
form.
The theoretical correlations are explained in the Proportional Hydraulics
textbook, Basic Level TP701. The technical description of the components used can be found in the data sheets in section D of this workbook.
The following additional training material for hydraulics is also available
from Festo Didactic:
Magnetic symbols
Hydraulic slide calculator
Set of overhead transparencies
Set of transparent models
Interactive video
Symbols library
Simulation program
11
Safety recommendations
The following safety advice must be observed in the interest of your own
safety:
Caution! Cylinders may advance as soon as the hydraulic power is

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

Use only extra-low voltage of up to 24V.
Observe general safety regulations (DIN 58126 and VDE 100).
Notes on procedure
Construction
The following steps are to be observed when constructing a control circuit.
1. The hydraulic power pack and the electrical supply unit must be
switched off during the construction of the circuit.
2. All components must be securely attached to the slotted profile plate,
i.e. safely latched and securely mounted.
3. Please check that all return lines are connected and all hoses securely connected.
4. Make sure that all cable connections have been established and that
all plugs are securely plugged in.
5. First, switch on the electrical power supply unit and then the hydraulic
power pack.
6. Make sure that the hydraulic components are pressure relieved prior
to dismantling the circuit, since:
Couplings must be connected unpressurised!
7. First, switch off the hydraulic power pack and then the electrical
power supply unit.
12
Technical notes
The following notes are to be observed in order to ensure trouble-free
operation.
An adjustable pressure relief valve has been integrated in the hydraulic power pack Part No. 152962. For reasons of safety, the system pressure has been limited to approx. 60 bar (6 MPa).
The maximum permissible pressure for all hydraulic components is

120 bar (12 MPa).
The working pressure is to be at a maximum of 60 bar (6 MPa).
In the case of double-acting cylinders, an increase in pressure may

occur according to the area ratio as a result of pressure transference.
With an area ratio of 1:1.7 and an operating pressure of 60 bar
(6 Mpa), this may be in excess of 100 bar (10 MPa)!
Fig. 2:
Pressure transference
If the connections are released under pressure, pressure is locked

into the valve or device via the non-return valve in the coupling. This
pressure can be reduced by means of a pressure relieving device
Part No. 152971. Exception: This is not possible in the case of hoses.
All valves, equipment and hoses have self-sealing couplings. These

prevent inadvertent oil spillage. For the sake of simplicity, these couplings have not been represented in the circuit diagram.
Fig. 3:
Simplified representation
of couplings
Flow
control valve
Hose
Shut-off valve
13
Notes on procedure regarding

proportional hydraulics
The sample applications for proportional hydraulics given here are
based on problems arising in industrial practice.
The technical solutions arrived at correspond to an open control loop
system in their method of operation.
Previous knowledge
Knowledge of the fundamentals as provided in the Festo Didactic workbook, TP701 are a prerequisite.
Fig. 4:
System design of
proportional hydraulics in
an open control loop system
Overall system
To be able to find solutions for problem definitions in proportional technology, the following technologies need to be combined in the system:
Hydraulics in general
Proportional valves, control electronics, setpoint generation
Signal control by means of relay technology and/or PLC
Signal generator
14
Power section
In the power section of a proportional hydraulic control system, the hydraulic drive, cylinder and motor are influenced with regard to:
Direction
Velocity/rotational speed
Force/Torque
Position
Owing to the particular mode of operation of continuous adjustability of

proportional valves and the variability of the control signals of the control
electronics, hydraulic drives can be assigned the following characteristics by means of a proportional final control element:
Velocity/rotational speed stages

Force/Torque stages
Specific deceleration
Smooth changeover in general
Signal control
The signal control section with the signal generators produces the desired sequence.
In the main, the type of control required in practice is process controlled
sequence control. A combination of time controlled operation and a logic
control system is often required. In practice, this is predominantly realised by means of PLC controllers.
Programming model for writing of PLC programs
In this workbook, a programming model is available in the form of sequence tables, whereby the appropriate program can be easily written
and converted with the individually available programming software. In
addition, a solution in relay technology has been prepared and tested.
15
Signal generator
Nowadays, hydraulic systems are optimised using a multitude of signal
generators.
The following are used in the training package TP702:
Binary signal function

Limit switch
Inductive sensor
Capacitive sensor
Optical sensor
Analogue signal function

Displacement sensor, potentiometric
Pressure sensor, piezoresistive
Temperature sensor, Resistance thermometer
Plus comparator card
Modes of operation and parameter conditions
In order to limit the extent of the exercises and to establish the essence
of proportional hydraulics, just a simple setting-up operation has been
integrated in some of the solutions.
Safety/Safety regulations
These are contained in the book purely with regard to the training operation. For reasons of space, safety regulations applicable in industrial
practice have not been taken into account.
16
Systematic problem solving

Particular importance has been attached to a systematic procedure for
problem solving: The structure of the solution has been designed so as
to meet this by way of the problem definition. The solutions of most of
the exercises have been structured as follows:
Understanding the exercise with the help of a positional sketch,
diagram and problem description
The problem definitions and descriptions use various diagrams in line
with industrial practice to illustrate the functional correlation of acceleration/deceleration in respect of time and distance. In proportional hydraulics, diagrams are the best form of describing sequences, whilst at same
time representing a part of the solution of the problem.
Design of the hydraulic circuit diagram
The design of the components is based on the equipment set of TP702.
Alternative solutions are possible. The use of solenoid switching valve
from equipment sets TP601 and TP602, further widens the possibilities
for solutions.
Determining the required signal generator
The diagrams call for a particular sequence. Signal generators initiate
the sequence of rapid traverse, acceleration, deceleration, etc. Once the
necessary signal generators have been considered and determined, the
signal control system can be prepared.
Preparing the sequence table
This facilitates the clear and systematic preparation of an example for
the PLC programming or circuit design.
Individual control steps are to be specified and the input and output signals of the signal control system defined. In addition, the setpoint values
and ramp addresses are to be specified.
17
Design of the electrical signal control system or writing of the PLC

program
As stated above, you are absolutely free to write your own individual
PLC program. For this workbook, TP702, relay controllers are to assume the signal processing function.
Electrical sequencers make good relay control systems. The defined
signals of the sequence table can be assigned step-by-step when designing the system. The relay control systems are to be described in the
solution description.
Construction and commissioning of the proportional hydraulic
controller
In exercise 1, a procedure is recommended as an example.
Setting values in the solutions
The setting values you have established can and may vary from the
values specifies. What is important is that the processes are practiceoriented and visually clearly arranged.
The basis for the setting values is the Festo Didactic standard hydraulic
power pack with q pump = 2 l/min.
Alternative solutions
The exercises in this book are based on the equipment set TP702.
Alternative solutions are of course also possible for the exercises set.
18
Harmonization
In order to reach optimum functioning of a proportional valve, valves,
control electronics, actuators and the hydraulic supply must be harmonized, whereby the following points are to be observed.
1. Problem definition
The problem definition provides a various basic data, which is important
with regard to both layout and harmonization. This includes the working
pressure, volumetric flow rate and the load of the consuming device as
well as the output flow of the hydraulic power pack.
2. Modulation
The proportional amplifier must be adapted to the valve. To do this, the
two limits according to which the adjustment is to be made must be
known. The first limit is formed by the nominal current of the proportional
solenoid, the other by the required or possible hydraulic value (pressure,
flow rate).
This adaptation can be achieved by means of setting the I MAX values,
whereby maximum current to be achieved with the maximum setpoint
value is determined. This prevents damage to the proportional solenoids
and at the same time simplifies the setpoint actuation, since a maximum
of only 10 V can be used as a setpoint value. Not even an inadvertent
overload is therefore no longer possible as far as the setpoint value is
concerned.
Since the maximum current can be set separately for each output, it is
for instance equally possible to balance different advancing and retracting speeds by means of different levels of I MAX values. Identical setpoint values for advancing and retracting also mean identical speeds.
19
3. Overlap
The overlap is the distance the valve piston needs to cover before the
control edges open. With this design, leakage can be kept to a minimum
even in the case of larger gaps around the valve piston. However, this
design has a disadvance with regard to actuation. Since the valve piston
re-adjusts in proportion to the magnetic flux, a certain amount of magnetic flux is necessary to overtravel this overlap. In the case of a proportional displacement valve, this means that flow will not start until a
certain setpoint value has been reached.
However, what is desirable is an ongoing adjustment of the flow from a
setpoint value of 0 to 10 V. This can virtually be achieved by means of a
the jump current I JUMP, whereby the required magnetic flux is established and set for each direction. Right from the lowest setpoint value,
an amount is added depending on the direction of the magnetic flux created by this setpoint value.
4. Basic current
If the drift of a cylinder or motor is to be compensated, this can be
achieved with a directional control valve by means of shifting the mid
position. By doing this, a greater leakage current is created on the side
of the smaller overlap, which acts against the drift. Another application is
in the sphere of the pressure control valve, where a specific pressure
level is to be maintained at a setpoint value of 0 V.
This shift is performed via the basic current I BASIC.
20
Amplifier characteristics for a proportional

directional control valve
Fig. 5:
Amplifier characteristic for a
proportional directional
control valve
21
Adaptation of the proportioal pressure relief valve to thedesignated

pressure setting range
1. Upper limiting value

As a rule, the designated highest pressure limiting value is set with
I MAX at a setpoint value of 10 V. This is also a safety factor in that it is
not possible to accidentally set a higher limiting value than that designated.
2. Lower limiting value

The lower limiting value of a system is generally connected to the circulation pressure of the pump without electrical connection. If the circulation pressue is for instance 7 bar, the basic current I BASIC at 0 volts is
set to this value.
An optimum setpoint value resolution is given for the specified pressure
setting range.
The electrical basic current once set remains permanently.
Amplifier characteristics for a proportional pressure

relief valve
Fig. 6:
Amplifier characteristic for a
proportional
pressure-relief valve
22
Training contents of Proportional Hydraulics

Advanced Level TP702
Establishing the characteristic curves and parameters of various sensors.
Harmonisation of electrical and hydraulic devices.

Measuring of variables such as pressure, temperature, displacement
and time.
Control of pressure, speed, acceleration, deceleration and position.

Reading and drawing up of proportional hydraulic and electrical circuit diagrams.
Reading of motion diagrams.

Application of symbols as specified in DIN/ISO 1219.
Construction and commissioning of proportional hydraulic control
systems including fault finding.
Adaptation and harmonization according to the specified sequence

description.
Use of basic circuits of proportional hydraulics such as for:
Velocity/rotational speed levels, acceleration/deceleration, differential

circuits, positioning.
23
List of training aims of the exercises

Exercises
Training aims
To be able to plot the characteristic curve of a pressure sensor.

To be able to realise the processing of the analogue signal from the
temperature sensor.
To be able to plot the characteristic curve of a temperature sensor.

To be able to realise the further processing of the analogue signal from
the displacement sensor.
To be able to plot the characteristic curve of a displacement sensor.

To be able to realise the further signal processing of the analogue signal
from the displacement sensor.
To be able to draw up a specified displacement-time diagram for a press

cylinder.
To be able to realise a specified positioning program.

To be able to set an accurate switch-off position.
To be able to realise the drive acceleration by means of a proportional

pressure relief valve.
To be able to realise the oscillating motion of a honing machine by

means of a proportional hydraulic control system.
To be able to realise a specified speed pattern by means of an additional

bypass circuit and softstop.
To be able to realise a injection moulding process using a worm motor

and tapered cylinder by means of a 2/2-way proportional valve and a
proportional pressure relief valve.
10
To be able to link two individual processes into one overall process.

To be able to effect an optimum interconnection of a proportional flow
control valve.
24
Equipment set Proportional hydraulics

Basic level TP701
Equipment set TP701
Order No. 184 465
Description
Order No.
Quantity
Relay plate, 3 off
162241
Signal input, electrical
162242
167087
Setpoint value card
162256
Proportional amplifier
162255
Pressure gauge
152841
Flow control valve
152842
One-way flow control valve
152843
Branch tee
152847
Pressure relief valve
152848
4/2-way solenoid valve
167082
Cylinder
152857
Hydraulic motor
152858
Proximity sensor, inductive
178574
Pressure filter
152969
Weight
152972
Pressure balance
159351
4/3-way proportional valve
167086
25
Equipment set Proportional hydraulics

Adavanced level TP702
Description
Order No.
Quantity
Relay plate, 3 off *)
162241
Time relay *)
162243
Indicator plate, electrical
162244
Cylinder mounting kit
120778
Comparator card
162257
Setpoint value card
162256
Non-return valve, 1 bar
152845
Branch tee
152847
Non-return valve, piloted
152852
Proximity sensor, capacitive **)
178575
Proximity sensor, optical*)
178577
Limit switch, electrical, left*)
183322
Limit switch, electrical, right *)
183345
Linear potentiometer
167090
Order No.
Quantity
Universal display
183737
Temperature sensor
184132
Pressure sensor
184133
Description
Equipment set TP702

Order No. 184 466
Additional components for

exercises 1 and 2
26
Additional components
for exercise 10
Accessories
Description
Order No.
Quantity
Pressure gauge
152841
Branch tee
152847
Hose 600 mm
152960
Relay plate, 3 off *)
162241
Time relay *)
162243
162255
Setpoint value card
162256
167082
167086
178574
Proximity sensor, capacitive
178575
Order No.
Quantity
Digital multimeter
035681
Hose 600 mm
152960
Hydraulic power pack
152962
Pressure relieving device
152971
Hose 1500 mm
159386
Power supply unit
159396
Set of cables
167091
Description
27
Relay plate, 3 off
Indicating device
Time relay, pick-up delayed
Zeitrelais, drop delayed
Non-return valve
Branch tee
Comparator card
Setpoint value card
Limit switch, electrical, left and right
Symbols of
equipment set TP702
28
Symbols of
equipment set TP702
Proximity sensor, optical
Pressure sensor
Temperature sensor
29
Allocation of components and exercises

Exercises
Components
Relay plate, 3 off
2
2
Signal input, electrical
1
1
1
1
1
1
Branch tee
3
1

1
Non-return valve
Cylinder
10*
Setpoint value card
Pressure gauge
Indicator plate
Time relay
Comparator
Hydraulic motor
Limit switch, electrical, left
Limit switch, electrical, right

Pressure filter
Set of cables
1
1
1
Power supply unit
Hose 600
Hose 1500
1
1
Universal display
Pressure sensor
Temperature sensor
Displacement sensor
12
1
1
1
1
* Exercise 10 requires a number of components, which are additional to those contained in equipment set TP700. In exercise 10, the circuits resulting from exercises 8
and 9 are linked to form a more complex overall function.
30
Methodical structure of the exercises

The workbook is structured in the form of exercises in section A and
solutions to exercises in section C. The methodical structure is identical
for all exercises.
The exercises in section A are divided into:

Subject
Title
Training aim
Problem definition
Problem description
Positional sketch
This is followed by the worksheet for the practical implementation of

the exercise using:
Block diagrams
Symbols for circuit diagrams
Setting aids
Evaluation aids such as
Value tables for measured values,
Coordinates for characteristic curves
Revision
The solutions in section C contain:

Hydraulic circuit diagram
Electrical circuit diagram
Component list
Setting table
Solution description
Evaluation
Conclusion
A-1
Section A Course
Exercise 1:
Exercise 2:
Exercise 3:
Exercise 4:
Exercise 5:
Exercise 6:
Exercise 7:
Exercise 8:
Exercise 9:
Pressure sensor
Characteristic curve, binary and analogue signal
A-3
Temperature sensor
A-9
Displacement sensor
Characteristic curve,
Basic control using displacement sensors
A-15
Curing press
Accelerating, delaying, velocity stages
A-25
Hydraulic lift
Interrupt positioning
A-33
Drawing press
Drive acceleration by means of
proportional pressure relief valve
A-41
Honing machine
Oscillation of hydraulic drives
A-49

Bypass circuit, soft stop
A-57

Simulation of complex injection
moulding processes
A-65
Exercise 10: Injection moulding machine with mould closing

device Overall process, proportional flow control
valve
A-73
A-2
A-3
Exercise 1
Proportional hydraulics
Subject
Pressure sensor
Title
Familiarisation with the mode of operation and signal processing of
Training aim
analogue sensors.
To specifically learn about the mode of operation and characteristic

curve of a pressure sensor.
To be able to understand and carry out the signal processing of

analogue signals by means of a comparator card.
Constructing the measuring circuit.

Plotting the characteristic curve of a pressure sensor.
Setting the threshold values.
Problem definition
A-4
Exercise 1
Problem description
For the purpose of integral quality assurance, state-of-the-art presses

have been equipped with control systems to monitor the pressing force.
In this way, the joining and pressing process is monitored for Good or
Reject parts. An analogue pressure sensor has been installed as a
signal generator for the pressure characteristics.
During the commissioning of the press, the characteristic curve of the
pressure sensor is to be checked and the threshold values 20 and 40
bar set subsequently as limit values for the monitoring
Fig. 1/1:
Positional sketch
Stroke
force
Monitored
range
Force
Good result
Stroke
A-5
Exercise 1
WORKSHEET
Plotting the characteristic curve for the overall pressure input

range
The analogue measuring encoder converts the measured physical

variable pressure into an analog electrical signal.
The input variable of the pressure sensor is the hydraulic pressure P

in the range of 0 to 100 bar.
The output signal of the pressure sensor is the normal electrical

standard voltage of 0 - 10 Volts.
Familiarise yourself with the components. See also the operating

instructions and data sheets.
Construct the complete measuring circuit. The hydraulic cylinder is

connected up in the form of a pressure intensifier, which means that
the retracted end position and rod chamber are filled with oil.
Check the origin of the characteristic curve:
Input signal = 0 bar, readable on the pressure gauge.

Output signa l= 0 Volt, readable on the comparator card.
Switch on the hydraulic power pack.
Use the pressure relief valve to accurately set the intensified pressures in accordance with the table.
Note the rising and falling measuring direction. Take a reading of the
allocated electrical voltage values.
Note that the pressure gauge must not be loaded in excess of 3/4 of
the maximum scale reading (75bar/7.5 MPa).
Enter the values in the table and draw the appropriate points in the
coordinate system.
Connect the points to form a characteristic line.
Evaluate the plotted characteristic curve and the characteristic curve

determined.
Plotting of
characteristic curves
A-6
Exercise 1
Fig. 1/2:
Circuit diagram, hydraulic
0-10 Volt
Fig. 1/3:
Circuit diagram, electrical
Selector switch
at IN A
A-7
Exercise 1
WORKSHEET
Measured
variable
and unit
Pressure
p in bar
Measured values
10
20
30
40
Measuring
direction
50
60
Value table
70
Voltage
V in volts
rising
Voltage
V in volts
falling
Fig. 1/4:
Characteristic line
Pressure/electrical voltage
A-8
Exercise 1
Conclusion
Explain the terms binary signal, binary signal generator, analogue signal
and analogue signal generator.
A-9
Exercise 2
Subject
Temperature sensor
Title
Familiarisation with the mode of operation of a temperature sensor.

To be able to understand and carry out the signal processing of
Training aim
analogue signals by means of a comparator card.
Designing the measuring circuit.

Checking the signal output of the temperature sensor.
Designing the temperature monitoring control.
Constructing and commissioning the temperature monitoring control.
Problem definition
A-10
Exercise 2
Problem description
Temperature monitoring
An oil temperature monitoring control is to be designed for exercises
4 to 10 in this workbook. This control should be easily integratable into
all of the solutions. A temperature sensor with a range of 0 to 100 C is
to be used to establish the temperature. First, the electrical output voltage analogous to the temperature is to be checked.
The following conditions apply with regard to the monitoring control.
The pump output temperature is to be established. The measured

value acquisition is therefore effected on the P-connection of the hydraulic power pack.
The ready status is designated to be from 25 C to 40 C. If the temperature exceeds or drops below this range, then the signal lamp is
to be illuminated and a restart should not be possible.
Fig. 2/1:
Positional sketch
A-11
Exercise 2
WORKSHEET
Checking the signal output within the possible oil temperature

range
The analogue measured value sensor converts the physical variable

temperature to be measured into an analogue electrical signal.
The input variable of the temperature sensor is the oil temperature T

within a range of 0 - 100 C.
The output signal of the temperature sensor is the normal standard

electrical voltage V from 0 10 V.
Familiarise yourself with the components.
See also operating instructions and data sheets.
Construct the entire measuring circuit.

Measure the currently existing electrical output voltage and take a
reading of the temperature allocated.

To do this, set the hand-held measuring device to temperature
measurement and the comparator card to electrical voltage measurement.
Switch on the hydraulic power pack.
Set a pressure drop of 50 bar with the help of the flow control valve.
A continually rising oil temperature is created as a result of the power
dissipation via the flow control valve (frictional and acceleration dissipation). This dissipation mainly heats the oil and a small part is emitted via the components due to heat emission. With this relatively high
power dissipation for our test, the temperature at the measuring point
rises rapidly, since the temperature of the oil supply is continually increasing.
Take a reading of the analogue electrical voltage values for the temperature measuring points specified.
Enter the values in the table.
Test procedure
A-12
Exercise 2
Fig. 2/2:
p 50 bar
Fig. 2/3:
Electrical circuit diagram
A-13
Exercise 2
WORKSHEET
Measured
variable and unit
Temperature
T in C
Voltage
V in volts
Measured values
25
30
Measuring
direction
Value table
40
rising
Fig. 2/4:
Logic diagram
Fig. 2/5:
A-14
Exercise 2
Conclusion
What are the advantages of using a temperature sensor and comparator card to monitor the temperature-ready status?
A-15
Exercise 3
Subject
Displacement sensor
Title
Learning about the mode of operation and characteristic curve of a
Training aim
displacement sensor.
To be able to understand and realise the further processing analogue signals by means of a comparator card.
Constructing the measuring circuit, attaching and adjusting the displacement sensor.
Checking the signal output of the displacement sensor.
Plotting the characteristic curve of a displacement sensor.
Designing the basic control.

Limit sensing on hydraulic drives by means of a displacement sensor
comparator card.
Constructing and commissioning the basic circuit.
Problem definition
A-16
Exercise 3
Problem description
Oscillating hydraulic drives, such as on honing machines and surface

grinding machines, have infinitely adjustable reversal point. Advanced
displacement sensors and comparator cards, provide an ideal solution
for end position sensing and infinite repositioning.
The signal output of the displacement sensor is to be checked within the
cylinder stroke range for an existing installation and the basic circuit
designed for the corresponding hydraulic drive.
The following conditions apply:
A start must only be possible when the retracted end position has
been reached.
It must be possible to infinitely reposition the forward reversal point

within a wide range.
The hyraulic circuit diagram, the displacement-step diagram and the
sequence table are specified, so that only the signal control remains to
be designed.
Fig. 3/1:
Positional sketch
Oscillations
A-17
Exercise 3
WORKSHEET
Checking the signal output of the displacement sensor within the

cylinder stroke range
The analogue measuring sensor converts the physical variable to be

measured, i.e. length, into an analogue electrical signal.
The input variable of the displacement sensor is the stroke length L

of 0 200 mm.
The output signal of the displacement sensor is the normal standard

electrical voltage V from 0 to 10 Volts.
Familiarise yourself with the components. See also operating instructions and data sheets.
Construct the entire measuring circuit.

Mount the displacement sensor.
The following data in the data sheet applies:
Sensor:
Mechanical stroke:
201 mm
Measuring stroke:
200 mm
Hydr. Cyl.: Stroke:
200 mm
During the assembly stage, the measuring slide is to be connected to

the cylinder rod so as to protect the measuring system, whereby the
mechanical end positions of the displacement sensor are not reached.
Theoretically, this should ensure that the signal 0 V or 10 V is supplied
in the cylinder end positions. This may vary subject to tolerances. The
training concept of TP 702 is designed for binary signal processing only,
whereby binary signal with a defined signal level of 0 V and 24 V are
available for the logic signal operation by means of threshold value generators (comparator card).
This means, that the zero point of the cylinder (retracted end position)
does not necessarily have to coincide with the zero point of the displacement sensor. For the retracted cylinder end position, for instance,
0.18 volts may be allocated. A threshold value generator would be set
slightly higher than this. See also basic control.
Test procedure
A-18
Exercise 3
The 4/3-way proportional valve with its control electronics is to be

used to position the hydraulic cylinder in accordance with the length
specified in the value table.
To do this, the internal setpoint value W1 of the control electronics is

to be activated via 24 volt signals, whereby the cylinder can be finely
adjusted using the setpoint generator. At the same time, set a jump
current I JUMP of approx. 50 mA for both directions, and an I MAX
current of approx. 800 mA.
Any type of tape measure may be used for the length measurement.
Read the allocated electrical voltage values in addition to the specified length values. With this, the values in the mechanical end positions of the hydraulic cylinder are important.
Considerable measuring errors may occur. However, the accuracy of

a measuring circuit and measured value acquisition of this type is
generally adequate to check the sensor function.
Note the values in the table and enter the corresponding points in the
coordinate system.
A-19
Exercise 3
WORKSHEET
Fig. 3/2:
Fig. 3/3:
A-20
Exercise 3
Value table
Measured
variable
and unit
Measured values
0
retracted
end position
Cylinder
stroke
in mm
50
100
150
Measuring
direction
200
forward
end position
Voltage
V in volts
rising
Voltage
V in volts
falling
Fig. 3/4:
Diagram
Stroke/voltage
V
Elektr.
Voltage
Cyl. stroke L
retracted
end position
forward
end position
A-21
Exercise 3
WORKSHEET
Designing the basic control for limit sensing on hydraulic drives

Given are the hydraulic power section, the displacement-step diagram
and the sequence table.
Design the electrical signal control for this.
Fig. 3/5:
Fig. 3/6:
Displacement-step diagram
front
Limits
rear
Setpoint
value
Setpoint value polling
Sequence table
Step
Sequence
1Y1 +
1Y2 -
I1
I2
I3
Rampsetting
Advance
W2 + 10 V
Zero
Retract
W1 - 10 V
Zero
A-22
Exercise 3
Fig. 3/7:
A-23
Exercise 3
WORKSHEET
Why is it necessary to fall below the threshold value with systems using
displacement sensors and a comparator card to detect the retracted end
position?
Conclusion
A-24
Exercise 3
A-25
Exercise 4
Subject
Curing press
Title
To be able to realise a required displacement-step diagram for a
Training aim
pressing cylinder.
Familiarising yourself using the positional sketch, displacement-time

diagram and problem definition.
Designing the hydraulic circuit diagram.

Defining the required signal generators in the displacement-time diagram.
Drawing up the sequence table.

Designing the electrical signal control.
Constructing the complete proportional hydraulic control system.
Commissioning:
Harmonizing of the proportional directional control valve and the
proportional amplifier.
Adjusting the signal generator.
Setting the required cylinder speeds by means of setpoint values.
Setting the acceleration and deceleration by means of ramps.
Fine-tuning of all the above points.
Problem definition
A-26
Exercise 4
Problem description
A curing press is used to cure a strip of wet imitation leather. The press
stamp is actuated by means of a double-acting hydraulic cylinder.
An optical sensor starts the squeezing cycle when the strip of leather
has been fed by an indexing conveyor belt.
The press stamp is accelerated to a high rapid traversing speed and is
then gently pushed down on the imitation leather. The squeezing position is kept under maximum pressure for an adjustable period of time.
This is followed by a partial return stroke and a smooth reversal of direction to maximum stroke speed. The cylinder with its squeezing press
now approaches the imitation leather on the conveyor without braking.
This is to ensure optimum squeezing as a result of this additional
pressing impact, prior to proceeding to the drying system.
The return stroke is effected by means of acceleration and gentle retracting into the initial position. The return stroke speed is reduced by
approx. 20 %, due to the weight of the press.
A signal is triggered in the lower end position in order to advance the
conveyor belt. The squeezing cycle is started again by the optical sensor.
Fig. 4/1:
Positional sketch
A-27
Exercise 4
WORKSHEET
Fig. 4/2:
Signal generator in the
displacement-time diagram
Displacement
Time
Cycle-time
Cycle-time
for conveyor
Fig. 4/3:
A-28
Exercise 4
Sequence table
Setpoint
value
Step
Sequence
Settingoperation
Advancing/
retracting with
optional stops
Automatic
Initial position
Acceleration
to stroke speed
Decelerating
to creep speed
Pressing for curing
Acceleration
for partial
return stroke
Smooth reversing
action for forward
stroke
Acceleration
to return stroke
speed
Deceleration
to creep speed
Initial position
Signal
generator
+ 1Y1
- 1Y2

I1
I2
I3
Ramp
Comment
A-29
Exercise 4
WORKSHEET
Fig. 4/4:
Signal control, electrical
A-30
Exercise 4
Fig. 4/5:
A-31
Exercise 4
WORKSHEET
Fig. 4/6:
A-32
Exercise 4
Harmonization of
Amplifier card
Selector switch
Display
FUNCTION
IA BASIC
IA JUMP
IA MAX
IB BASIC
IB JUMP
IB MAX
DITHERFREQ
Conclusion
What are the setting measures used during commissioning to achieve

the optimum setting of the motion sequence?
A-33
Exercise 5
Subject
Hydraulic lift
Title
To be able to realise a required positioning diagram with accurate
Training aim
switch-off positioning.
Familiarising yourself with the exercise using the speed-displacement

diagram and problem description.

Defining the required signal generators in the speed-displacement
diagram.

Commissioning:
Harmonizing the proportional directional control valve and proportional amplifier.
Setting the required speeds by means of setpoint values.
Fine-tuning all of the above points.
Problem definition
A-34
Exercise 5
Problem description
A block of flats with four floors has been designed with a hydraulic lift.
The lift cabin is actuated by means of a hydraulic telescopic cylinder.
Upward and downward travel to the respective floor positions must take
place in accordance with the specified positioning diagram.
Positioning during upward travel of the lift is effected by means of deceleration on creep speed and stopping once the position has been
reached. When travelling downward, the designated higher lowering
speed must be smoothly decelerated in two stages.
In order to limit the extent of the exercise, the signal control is designed
merely for upward and downward travel into the respective positions.
Any other signal logic for several floors, generally used for a lift, are
omitted. Similarly, none of the safety regulations and requirement applying to the hydraulic and electrical control have been taken into account.
For this exercise, the telescopic cylinder is replaced by a double-acting
cylinder.
Fig. 5/1:
Positional sketch
A-35
Exercise 5
WORKSHEET
Fig. 5/2:
Signal generator with
positioning diagram
VLift
Position
Creep speed
Creep
speed
VLower
Displacement
A-36
Exercise 5
Fig. 5/3:
A-37
Exercise 5
WORKSHEET
Sequence table
Step
Setting
operation
Sequence
Advancing/
retracting with
optional stops
Acceleration
to stroke speed
Deceleration
to creep speed
Positioning
Acceleration
to lowering
speed
Deceleration
to creep speed
II
Deceleration
to creep speed I
Positioning
Signal
generator
Setpoint
value
Setpoint value
polling
+ 1Y1
- 1Y2
I1
I2
I3
Amplifier
output
Ramp
OA
A
OA
B
1Y3
Comment
A-38
Exercise 5
Fig. 5/4:
A-39
Exercise 5
WORKSHEET
Fig. 5/5:
A-40
Exercise 5
Harmonization of
Amplifier card
Selector switch
Display
FUNCTION
IA BASIC
IA JUMP
IA MAX
IB BASIC
IB JUMP
IB MAX
DITHERFREQ
Conclusion
Does the switching time of the electrical signal control influence the position during stopping?
A-41
Exercise 6
Subject
Drawing press
Title
To be able to realise the drive acceleration by means of a propor-
Training aim
tional pressure relief valve.
Familiarising yourself with the exercise using the positional sketch,

displacement/time diagram and problem description.

Defining the required signal generators.
Commissioning:
Harmonising the proportional pressure valve and proportionalamplifier.
Setting the required pressure values by means of setpoint values.
Setting the acceleration by means of ramps.
Fine-tuning all of the above points, including the harmonisation of
the amplifier.
Problem definition
A-42
Exercise 6
Problem description
Hydraulic drawing presses are machine tools used for non-cut forming
operation. Hollow parts are deep drawn from sheet steel. The pressure
pad decelerates the material flow into the drawing gap and eliminates
tearing. The pressure pad force originates from the pressure springs.
The drawing tool is actuated by a hydraulic cylinder. The forming process must start smoothly with reduced force and then increase via
ramps; the metal is thus able to flow and does not tear.
The load of the drive and the mechanical structure is to be kept as low
as possible. This is to be achieved by means of a smooth reversal of
direction after drawing and acceleration for the return stroke, as well as
a low pressure stage for retracting into the initial position.
Fig. 6/1:
Positional sketch
Drawing ring
Pressure pad
Drawing tool
A-43
Exercise 6
WORKSHEET
Fig. 6/2:
Signal generator in
Pressure-time diagram
Pressure
p Prop.DBV
Drawing
advance
Drawing operation
Time t
sec.
Return stroke
Fig. 6/3:
A-44
Exercise 6
Sequence table
Setpoint
value
Step
Sequence
Acceleration for
advancing and
drawing action
Preparing return
stroke Start Time function
Acceleration for
return stroke
Low pressure
stage for smooth
retracting
Initial position
Signal
generator
+ 0Y
Setpoint value
polling
I1
I2
I3
Ramp
1Y
Comment
A-45
Exercise 6
WORKSHEET
Fig. 6/4:
A-46
Exercise 6
Fig. 6/5:
A-47
Exercise 6
WORKSHEET
Selector switch
Display
Harmonization of
Amplifier card
FUNCTION
IA BASIC
IA JUMP
IA MAX
IB BASIC
IB JUMP
IB MAX
DITHERFREQ
What conditions must be specified in the process sequence in order to

facilitate the acceleration for the hydraulic drive by means of a proportional pressure relief valve?
Conclusion
A-48
Exercise 6
A-49
Exercise 7
Subject
Honing machine
Title
To be able to realise the oscillating movement of a honing machine
Training aim
Problem definition
by means of a proportional hydraulic control system.
displacement-time diagram and problem description.

Defining the required signal generator in the displacement-time diagram.

Commissioning:
Harmonising the proportional directional control valve and the proportional amplifier.
Adjusting the linear potentiometer.
Setting the threshold value generator of the comparator card.
Setting the honing speed by means of setpoint values.
Setting the reversing process by means of ramps.
Fine tuning of all of the above points.
A-50
Exercise 7
Problem description
Honing machines are used to surface finish bored holes. It must be possible to achive optimum adaptation of the motion sequences to the machining conditions.
Required are: Standard and short stroke honing with infinite relocatable
reversing points and accurate reversing accuracy, plus high adjustable
honing speeds.
The reversing process is to be quick, but nevertheless smooth running.
The honing should be adjustable, whilst it should also be possible to
terminate manually. On completion of the honing, the hydraulic drive is
to return smoothly to its initial position.
Fig. 7/1:
Positional sketch
A-51
Exercise 7
WORKSHEET
Fig. 7/2:
Signal generator in
Displacement
Standart and short-stroke honing within overall stoke range
Strokerange
Time
Fig. 7/3:
A-52
Exercise 7
Sequence table
Setpoint
value
Step
Sequence
Setting
operation
Advancing/
retracting with
optional stops
Automatic
1
Approach and
honing start
2, 4 ...
Honing
return stroke
3, 5 ...
Honing
forward stroke
Signal
generator
+ 1Y1
- 1Y2
Setpoint value
polling
I1
I2
I3
Ramp
Comment
Continuous
operation
STOP
n+1
Soft stop
n+2
Initial position
A-53
Exercise 7
WORKSHEET
Fig. 7/4:
A-54
Exercise 7
Fig. 7/5:
A-55
Exercise 7
WORKSHEET
Selector switch
Display
Harmonization of
Amplifier card
FUNCTION
IA BASIC
IA JUMP
IA MAX
IB BASIC
IB JUMP
IB MAX
DITHERFREQ
How is it possible to carry out a smooth reversal of direction during an

oscillating motion in proportional hydraulics?
Conclusion
A-56
Exercise 7
A-57
Exercise 8
Subject
Moulding closing device
Title
To be able to realise a required speed pattern with soft stop by
Training aim
means of an additional bypass circuit.
Familiarising yourself by means of the positional sketch, speed-time

diagram and problem description.

Defining the required signal generators in the speed-time diagram.
Commissioning:
Harmonising the proportional directional control valve and proportional amplifier.
Setting the required cylinder speed by means of setpoint values.
Setting the acceleration and delays by means of ramps.
Fine-tuning all of the above points.
Problem definition
A-58
Exercise 8
Problem description
A mould closing unit for an injection moulding machine is to be opened

and closed by means of a toggle lever mechanism. The mechanism is to
be actuated by a double-acting hydraulic cylinder.
In order to achieve a short cycle time, 90% of the closing process is to
be effected at high speed. The last part of the closing movement is to be
decelerated to a low speed, thereby producing a high closing force.
When the injection moulding time has elapsed, the mould closing unit is
to be gently opened and returned at high speed. The initial position is
reached with a soft stop.
In order to obtain an optimum pump design with regard to large volumetric flow rate and effective pressure, the hydraulic control system is to be
designed with an interruptable bypass circuit.
Fig. 8/1:
Positional sketch
A-59
Exercise 8
WORKSHEET
Speed
(m/s)
Mould
closed
Mould
open
Fig. 8/2:
Signal generator in
V-t diagram
Close
Open
Time
(s)
Closing time
Fig. 8/3:
A-60
Exercise 8
Sequence table
Setpoint
value
Step
Sequence
Acceleration
to high
closing speed
Deceleration to
closing speed
High closing force
Signal
generator
+ 1Y1
- 1Y2
Setpoint value
polling
I1
I2
I3
Ramp
1Y3
Comment
Holding of closed
mould
Acceleration
to opening
speed
Deceleration
to creep
speed
Deceleration
in end position
Initial position
A-61
Exercise 8
WORKSHEET
Fig. 8/4:
A-62
Exercise 8
Fig. 8/5:
A-63
Exercise 8
WORKSHEET
Selector switch
Display
Harmonization of
amplifier card
FUNCTION
IA BASIC
IA JUMP
IA MAX
IB BASIC
IB JUMP
IB MAX
DITHERFREQ
What is the advantage of the hydraulic bypass circuit in the exercise

set?
Conclusion
A-64
Exercise 8
A-65
Exercise 9
Subject
Title
To be able to realise an injection moulding process using a worm
Training aim
motor and injecting cylinder by means of a 2/2-way proportional

flow control valve and a proportional pressure relief valve.

speed/pressure characteristics diagram and problem description.

Defining the time and process-controlled steps.
Commissioning:
Harmonising the proportional flow control valve, proportional pressure relief valve and proportional amplifier.
Setting the required speeds, velocities and pressure levels by
means of setpoint values.
Fine-tuning of all of the above points, including harmonization of
the amplifier.
Problem definition
A-66
Exercise 9
Problem description
An injection moulding machine is used to produce rubber and plastic

parts. The hydraulic drive is controlled in such a way that the plasticizing
speed and injection pressure produce an optimum injection moulding
process.
A hydraulic motor drives the worm, which plasticizes the plastic granulates due to thermal effect. The rotary speed characteristics are defined
according to the plasticizing process, thereby creating pressure for the
return stroke of the injecting cylinder. The hydraulic counter pressure is
controlled in such a way as to achieve an optimum plasticizing process.
The plasticized granulate is then injected, whereby the injecting speed
and pressure have corresponding characteristics.
After the injection phase, the hydraulic pressure is briefly raised to a
specified consolidating pressure level.
Once the granulates have been injected, a new plasticizing and injection
moulding process begins; in our example, this is started manually.
Fig. 9/1:
Positional sketch
A-67
Exercise 9
WORKSHEET
Fig. 9/2:
Signal generator
in diagram
Speed and pressure characteristics

min
-1
Time
(s)
Cylinder
Counter pressure
during plasicising
process
Injecting
Granulate
filling
time
Time
New (s)
cycle
Consolidating pressure
A-68
Exercise 9
Fig. 9/3:
A-69
Exercise 9
WORKSHEET
Sequence table
Proportional flow control valve

Time and process oriented
sequence
Step-No.
Sequence
Accelerate motor
to n1
Accelerate motor
to n2
Decelerating motor
to standstill
Accel. injecting cyl.

to V1
Accel. injecting cyl.

to V2
6
Initial pos.
Setpoint
value
1Y1

I1
I2
I3
Ramp
Comment
Cylinder advanced
Sequence table

sequence
Step-No.
1Y3
Sequence
Counter pressure
32 bar
Counter pressure
20 bar
Counter pressure
30 bar
Injection moulding
pressure to 45 bar
Injection moulding
pressure to 57 bar
6
Counter pressure
Initial pos. 40 bar
Setpoint
value
1Y1

I1
I2
I3
Ramp
1Y3
Comment
A-70
Exercise 9
Fig. 9/4:
A-71
Exercise 9
WORKSHEET
Fig. 9/5:
A-72
Exercise 9
Harmonization of
Amplifier card
Selector switch
Display
FUNCTION
IA BASIC
IA JUMP
IA MAX
IB BASIC
IB JUMP
IB MAX
DITHERFREQ
Conclusion
Under what conditions is it possible to control several hydraulic drives in

a system using a proportional flow control valve?
A-73
Exercise 10
Subject
Injection moulding machine with mould closing device
Title
To be able to link two individual processes into one overall process.

To be able to effect an optimum interconnection of proportional flow
Training aim
To carry out the exercise with the help of exercise 8 mould closing
Problem definition
control valves.
device and exercise 9 injection moulding machine.
Representing the overall process in function chart.

Designing the electrical signal control to link the two individual proc-
esses of mould closing and injection moulding into one overall process.
Integrating the logic operation stage and commissioning the overall

installation.
Completing the exercise sheet Proportional flow control valves.
A-74
Exercise 10
Problem description
The two individual installations mould closing device and injection

moulding machine from exercises 8 and 9 are to be linked in such a
way as to create one overall process.
To achive this, the signal control needs to be amended and a corresponding interface connection designed and integrated.
Fig. 10/1:
Positional sketch
A-75
Exercise 10
WORKSHEET
Fig. 10/2:
Function chart
A-76
Exercise 10
Fig. 10/3:
Signal diagram, electrical
A-77
Exercise 10
WORKSHEET
Why should the correlations in regard to a control task first of all be considered and recorded neutrally, e.g by means of a function chart or
function diagram?
Conclusion
A-78
Exercise 10
Describe the functions of the proportional flow control valves in the

circuits below.
Design the same circuit diagram with the help of the 4/3-way proportional valve from the equipment set TP702.
Circuit diagram with 2/2-way

proportional valve and 4/2way proportional valve
Description
Circuit diagram with

B-1
The theoretical fundamentals for the training package Proportional Hydraulics are summarised in the following textbook:
Learning System for Automation and Communications
Proportionalhydraulics
Basic Level TP701
C1
X C2 Y
B-2
C-1
Section C Solutions
Solution 1:
Pressure sensor
Solution 2:
Temperature sensor
C-13
Solution 3:
Displacement sensor
C-17
Solution 4:
Squeezing press
C-25
Solution 5:
Hydraulic lift
C-35
Solution 6:
Drawing press
C-49
Solution 7:
Honing machine
C-55
Solution 8:
C-63
Solution 9:
C-71
Solution 10:
Injection moulding machine with

mould closing device
C-79
C-3
C-2
C-3
Solution 1
Pressure sensor
Plotting of characteric curve
The characteristic curve for the entire measuring range of 0 100 bar is
possible by connecting the hydraulic cylinder in the form of a pressure
intensifier.
Cylinder characteristics from the data sheet:
Maximum permissible pressure:
120 bar
Piston diameter:
16 mm
Piston rod diameter:
10 mm
A surface ratio of piston to annular surface of 1.641 is obtained. The
maximum adjustable limiting pressure on the hydraulic power pack is
60 bar or at the most 61 bar, so that the intensified pressure can be adjusted up to
61 bar 1,641 100 bar
The maximum permissible operating pressure of the pressure sensor is
thus not exceeded. In the static range the pressure should not exceed
3/4 of the full scale value. Therefore a maximum pressure of 75 bar is
the upper limit for a plot of the characteristic line.
The accuracy of the plotted characteristic line is dependent on the precision of the measuring devices used and the accurate implementation of
the test.
Measuring of input variable
When plotting the characteristic line, the input variable of the pressure
sensor is measured by means of a pressure gauge. Pressure gauge
characteristics from the data sheet:
Measuring range:
0 100 bar
Measuring accuracy:
1.6 % corresp. to. Kl 1.6

Tolerance is 1.6 % of maximum scale reading
across the entire measuring range
Measuring of output variable

The comparator card is intended for the measurement of the output
variable. To do this, the selector switch is set to IN A, and the electrical
voltage of the pressure sensor applied to input A.
The measuring circuit and the measuring devices used, are generally
adequate for an on-the-spot functional check.
C-4
Solution 1
Evaluation of characteristic line

The diagram produces the following characteristics:
Input range:
100 bar
Output range:
0-10 Volt
Measuring range: 100 bar, adequate also for pressure intensification

Hysteresis:
The reduced hysteresis is a favourable characteristic

of the pressure sensor (not specified in the data
sheet).
Linear range:
The permissible linear deviation quoted in the data

sheet of 1.6 % cannot be detected. The linear
range extends across the entire characteristic line
with origin zero (proportional correlation).
Setting the threshold values

The threshold values (setpoint values) are selected using the selector
switch and set by means of the setting knob and the threshold value
(setpoint value) set. The setpoint values are to be taken from the value
table. The triggered switching operation is displayed via the corresponding LED`s.
C-5
Solution 1
Measured
variable
and unit
Measured values
Measuring
direction
Pressure
p in bar
10
20
30
40
50
60
70
Voltage
V in volts
0.0
0.9
1.9
2.9
3.9
4.9
5.9
6.8
rising
Voltage
V in volts
0.0
6.9
falling
Evaluation
Value table
Fig. 1/1:
Characteristic line
Pressure/electrical voltage
C-6
Solution 1
Conclusion
Signals/Signal generators
Signal generators of equipment set TP702
Measured variable
Signal generator
Analogue
Volumetric flow rate*

Pressure
Temperature
Displacement
Binary
Volumetric flow sensor

Pressure sensor
Temperature sensor
Displacement sensor
Proximity sensor.
inductive, capacitive and
optical Limit switch
Position
* contained in Festo Didactic case only
Binary signals/Binary signal generators

Binary bivalent
The information form of using two values On and Off (1 and 0) permits the processing the logic operations and represents the signal processing in control technology.
Binary signal generators are limit switches

The physical variable is dtected on a designated value using the socalled limit switches (also known as threshold value indicators). The limit
switch supplies a defined signal when the limit switch reaches the set
value. If the value is fallen below of, the signal changes to the equivalent
value. In control technology, the two values are predominantly allocated
24 Volt and 0 Volt.
Limit value setting
Limit switch:
Pressure switch:
Proximity switch:
Comparator card:
Push button:
Positioning during assembly

Pretensioning of the spring
Positioning during assembly
Threshold value setting
Given by the spring force
C-7
Solution 1
Displacement
Temperature
Pressure
Fig. 12:
Function of a limit switch
Hysteresis
Physical variable
characteristic
Threshold value with

increasing value
Threshold value with

falling value
Time
Switching
signal
Time
Switching hysteresis
Switching of the signal from 0 to 1 and vice versa does not take place
linearly, but according to a specific difference of the physical variable.
The difference is created as a result of the characteristics of the switching device, mainly friction.
In the case of advanced threshold value indicators, such as the Festo
Didactic comparator card, the hysteresis value can be set within a large
range, whereby the setting value zero is also possible.
The advantages of hysteresis setting facilities manifest themselves, for
example, in the case of two-step control, since the switching frequency
of the threshold value indicator is halved as a result of the limit value
interrogation.
C-8
Solution 1
Analogue signals/analogue signal generators

Analogue multivalent
Signal generator function

The signal level continually follows the pattern of the physical variable
and always supplies the momentary value, the absolute value.
In the case of the analogue sensors of training package TP702, it is the
standard electrical voltage of 0 to 10 Volt.
Fig. 1/3:
Signal pattern
Displacement
Temperature
Pressure
Physical variable
characteristic
Time
Electrical voltage
Electrical current
Analogue
signal
Time
C-9
Solution 1
Analogue signal processing is the signal processing of analogue control

technology. The current value of the physical variable is continually
available for signal processing in the form of a voltage or current signal
and is continually processed. The extra information is necessary in
control technology and requires correspondingly more complex signal
processing.
In control technology, analogue signals can be detected at any number
of values by means of a threshold value indicator and then processed as
a binary signal. Comparator cards are ideal for this.
Comparator cards as a universal analogue-to-binary converter and
threshold value indicator in control technology.
In control technology, the electrical analogue signals from analogue
sensors can be easily detected at any value by means of comparator
cards and then processed into binary signals.
The advantages of advanced comparator cards:
Numerous threshold values can be set.

Setting can be easily changed.
Remote control, since the threshold value indicators are connected to
the sensor via an electrical line. (A mechanical pressure switch can
only be set at the actual point where it is installed.)
The threshold values can be set more accurately.

The hysteresis is adjustable. This is an advantage with certain connection methods.
C-10
Solution 1
Fig. 1/4:
Function of
Comparator card
(see also data sheet)
Displacement
Temperature
Pressure
Physical variable
characteristic
Time
Electrical voltage
Physical variable
characteristic
Hysteresis,
adjustable
Time
Switching
signal
Time
C-11
Solution 1
Terminology and meaning

Sensors are also known as signal converters, signal detectors, and in
connection with closed control loops as measuring transducers or
measuring systems. See also the Festo Didactic Workbook TP 511.
Hysteresis, Hysteresis loop
A hysteresis loop is created when the output variable as a function of
the input variable is recorded over the whole range. The largest difference of the input variable for an identical output signal is specified as a
hysteresis value in a percentage of the maximum signal value in the
data sheet.
Linearity
This refers to the maximum deviation between the ideal linear characteristic and the measured characteristic within the linear range. In data
sheets, the deviation is specified in a percentage of the maximum signal
value.
Fig. 1/5:
Hysteresis and linearity
Output variable,
e.g.
elect. voltage
Linearity
Hysteresis
Input variable,
e.g. pressure
C-12
Solution 1
Components list, hydraulic
Components list, electrical
Item
Description
Double-acting cylinder
Pressure sensor
Pressure gauge
Hose
Item
Description
Power supply unit
Comparator card
Set of cables
C-13
Solution 2
Temperature sensor
Measured variable
and unit
Measured values
Measuring
direction
Temperature
T in C
25
30
40
Voltage
V in volts
2.51
3.01
4.02
Value table
rising
Checking of temperature sensor
Principle of analogue temperature sensor

This resistance thermometer utilises the analogue allocation of electrical
resistance to temperature.
Our sensor is used to detect the temperature using a Pt 100 measuring
element, whereby the platinum resistance element used has an electrical resistance of 100 at 0 C. This value is defined as a nominal resistance and described as Pt resistance. Platinum has a positive
temperature coefficient. Rising temperature means increasing electrical
resistance. The resistance change is converted into a measuring signal
electronically and amplified.
The standard voltage 0 - 10 Volt is available analogous to the input
range.
Installation
The sensor is built into a hydraulic connector and, like all the other components of equipment set TP702, it can be pressurised up to 120 bar.
The sensor can therefore be used to check or monitor the pump output
temperature as an important measuring point or the cylinder input pressure after a flow control action.
Measuring circuit
Our measuring circuit is not intended for the plotting of a characteristic
line, but to record the electrical output voltage. This output voltage is
also evaluated for the temperature display.
In order to plot a characteristic curve, the temperature would have to be
recorded separately. If required, this can be effected with an additional
temperature sensor of equipment set TP702. In order to plot a complete
characteristic line, the output signal must be recorded with rising and
falling temperature. As such, the electrical voltage values deviate from
one another in relation to the identical temperature measuring point. If
the range is traversed in both directions, this results in a hysteresis loop.
Evaluation
C-14
Solution 2
Fig. 2/1:
Logigplan
YESfunction
Lamp
NOTfunction
ORfunction
Controller
ANDFunktion
Fig. 2/2:
Schaltplan, elektrisch
Signallamp
Start signal
memory
of exerc. 4-10
C-15
Solution 2
Logic
The signal logic operation can be described as follows:
If 25 C is not achieved, or 40 C exceeded, the signal lamp is to be
illuminated and a re-start is not possible.
A logic diagram enables you to describe the signal logic irrespective of
technology. In our solution, the hardware realisation is effected by
means of relays and their contacts. The symbols and the logic diagram
have been standardised in DIN 40700, Part 14.
Threshold value generator of comparator card
The electrical analogue voltage values to 25 C and 40 C have been
established by you using approx. 2.5 V and 4.0 V.
These voltage values are now set as threshold values for input A of the
comparator card. To do this, use the selector switch to select S A1" for
the value 2.5 V or S A2" for 4.0 V, and set the values with the adjuster.
When the input voltage now reaches these threshold value settings,
contacts A1 or A2 will switch. If the input voltage drops below the values
set, the contacts will open. (Strictly speaking, the value determined in
the falling measuring direction must be taken as the threshold value,
when failing to meet the lower limit). In order to bring about the switching and returning with the same voltage value, the hysteresis H A1" and
H A2" of the comparator card is set at zero.
See also the operating instructions and technical data in the appendix.
When temperature monitoring in a production system, a range of 40 C
to 55 C is usual for a steady-state tank temperature. However, these
temperatures are not achieved during short-time operation, e.g. such as
for training.
Set your own individual values.
C-16
Solution 2
Integration of hydraulics, electro-hydraulics and proportional hydraulics in Festo Didactic exercises

You can use the control system for temperature monitoring in all the
exercises. Naturally, in the case of hand lever hydraulics, only an optical
display is possible.
Conclusion
For ready status monitoring, several limit values must be detected and
supplied to a corresponding signal logic.
For example:
Critical upper and lower oil temperature for the cooling circuit, possibly
also heating.
A temperature sensor and comparator card represent the ideal means
for a solution.
Item
Description
Flow control valve
Temperature sensor
Pressure gauge
Hose
Item
Description
Power supply unit
Universal hand measuring device
Comparator card
Relay, 4-off change-over contacts
Signal lamp (LED)
Set of cables
C-17
Solution 3
Displacement sensor
Measured
variable
and unit
Measured values
Measuring
direction
Cylinder
stroke
in mm
0
retracted
end position
50
100
150
200
forward
end position
Voltage
V in volts
0.18
2.5
5.04
7.53
9.99
rising
Voltage
V in volts
0.18
2.49
5.02
7.50
falling
Evaluation
Value table
Fig. 3/1:
Stroke/voltage
characteristic
V
Electr.
Voltage
Cyl. Stroke L
Retracted end
position
Forward end
position
Evaluation of measuring results:
The linear range extends across the entire measuring range.

A hysteresis cannot be detected with the measuring method used.
C-18
Solution 3
General information regarding the potentiometer

The linear potentiometer converts the physical variable displacement
into an electrical voltage. This is effected according to the voltage divider principle: On an ohmic resistor Rtot with the input voltage Vi, the
voltage Vo is tapped via the resistor R at any point:
Vo = Vi
R
R tot
Voltage divider formula
Since the resistance is proportional to the length L of the potentiometer,

this results in:
Vo = Vi
L
L tot
Fig 3/2:
Electrical voltage divider
Rtot
(Ltot)
Wiper
Vi
R
(L)
Vo
Fig 3/3:
Construction and
connection of
linear potentiometer
Vi
Vo
Rtot
R
Ltot
L
= Input voltage
= Output voltage
= Total resistance
= Partial resistance
= Total length
= Wiper position
Reference voltage supply

red
black
white
blue
Cable plug
Integrated into cable
Impedance converter
C-19
Solution 3
Reference voltage supply

The reference voltage supply is an electronic module, which ensures a
high-precision voltage. This voltage is used to supply the potentiometer.
Fluctuations in supply voltage do not affect the reference voltage.
Impedance converter
If current passes through a consuming device on the signal output of the
linear potentiometer, then the voltage divider is on-load and the tapped
voltage therefore changed.
An impendance converter, also known as a isolation amplifier, keeps the
potentiometer virtually load-free. The signal voltage remains unchanged.
The impendance converter with protective circuit is casted into the potentiometer cable. At the same time, this circuitry protects the potentiometer from damage when interchanging the connections.
C-20
Solution 3
Fig. 3/4:
Fig. 3/5:
Displacement-step diagram
front
Limits
rear
C-21
Solution 3
Fig. 3/6:
C-22
Solution 3
Basic control for limit sensing by means of displacement sensor

and comparator card
Retracted end position
In order for a switching action to be triggered in the retracted end position, a lower than set threshold value is to be recorded. As already described during the assembly of the potentiometer, the potentiometer
signal value zero or better still a small voltage value can be emitted at
the cylinder end position which, when slightly increased, represents the
threshold value.
In our control system, the threshold value indicator A1 with its normally
closed contact is used, since the logic operation is a NOT-function:
When the set threshold value is NOT reached any longer, then the retracted end position has been reached. The A1 normally closed contact
of the comparator card is closed and the required Start precondition is
given.
This connection also applies for a retracted position in front of the mechanical cylinder stop.
Forward end position
The signal processing is as usual. When the forward threshold value A1
is reached, its normally open contact closes the relay circuit KA2,
thereby initiating the return stroke.
This connection also applies in the case of a forward position in front of
the mechanical cylinder stop.
Intermediate switching points
A triggered switching action of the threshold value contacts during advancing remains intact.
This switching action is reset during retracting and when falling below
the threshold value.
For limit sensing by means of electrical threshold values, see also exercise 7, honing machine..
C-23
Solution 3
At the point of falling below of the threshold value, the threshold value
relay is de-energised.
Conclusion
A circuit can be opened or closed by means of the relay contacts.
Item
Description
Pressure filter
Hose
Item
Description
Power supply unit
Setpoint value card
Linear potentiometer, complete with mounting kit
Comparator card
Push button Start
Set of cables
C-24
Solution 3
C-25
Solution 4
Squeezing press
Fig. 4/1:
Fig. 4/1:
Signal generator in
Displacement
Stroke
Time
Cycle-time
Cycle time
C-26
Solution 4
Sequence table
Setpoint
value
Signal
generator
+ 1Y1
- 1Y2
Advancing/
Settingretracting with
operation optional stops
Selector switch
AUTO/SET
W1
0 bis + 10 V
0 bis - 10 V
Automatic
Initial position
Selector switch
and B1
W8
0.5 volts
Acceleration
to stroke speed
Start B0
W2
+ 10 volts
R1
Start via
0.10 S/1 V optical sensor
Decelerating
to creep speed
1S1
W3
+ 2.5 volts
R2
0.05 S/1 V
Pressing for
curing
1S2
W3
Acceleration or
partial return
stroke
Time signal
W4
- 7 volts
R3
Time expired
0.05 S/1 V
Smooth reversing
action for forward
stroke
1S1
W5
+ 10 Volts
R4
0.05 S/1 V Forward stroke to
stop without decelR1
0.10 S/1 V eration
Acceleration to
return stroke
speed
1S2
W6
- 8 volts
R3
Deceleration to
creep speed
1B2
W7
3.5 volts
R4
Initial position
1B1
W8
Step
Sequence
I1
I2
I3
Ramp
Comment
For commissioning
e.g. testing of signal
generator position
Set to
zero
Cylinder is pressurised in retracted end

position
Start of time function
C-27
Solution 4
Fig. 4/3:
C-28
Solution 4
Fig. 4/4:
set
AUTO/SET
C-29
Solution 4
Fig. 4/5:
Separate
power supply
C-30
Solution 4
Training content
In this example, the training contents of the workbook TP701, Basic
Level, are summarised and covered once more.
The solution method for this more complex problem definition is incorporated into the structure of the problem. Of major importance is the sequence table, which is used to define the individual steps of the signal
control. The sequence table thus forms the blue print for the design of
the signal control.
Signal generator
Required are signal generators with binary signal function. The connection of the inductive, capacitive and optical sensors can be effected in
the intended way, since the signal outputs of the binary sensors from
the training package TP702 are fitted with a diode. If allocated as an
input, the connection is closed.
Signal control
The type of control required is a process-controlled sequence control. A
resetting relay sequencer system is suitable for this, which is used in
this exercise.
In this exercise, the setting of a stage in the sequence via the corresponding signal generator means:
Output signals for setpoint value polling.

Preparation of subsequent stage.
Resetting of previous stage.
This also means that for the start, the last (previous) stage must be prepared, i.e. set. If the electrical control energy is switched on, then the
previous stage must be set either automatically or by means of a manually set signal, thereby preparing the signal control for the start. An
automatic setting process is shown by a dashed line.
The prepared signal control with its output signals produces the output
position of the hydraulic drive, which is defined in the sequence table.
The setpoint value W8 is switched; the cylinder is pressurised in the
retracted end position.
C-31
Solution 4
In general, the following procedure applies for the connection of

energy:
1. Switch on the electrical control energy.
2. Connect the hydraulic energy.
In our example, the electrical sequencer also needs to be set prior to
switching on the hydraulic pump.
For instance, if the sequencer is not set and the hydraulic pump is
switched on, then the setpoint value W1 for the setting operation is active. The automatic setting process drawn in a dashed line would of
course prevent this.
Construction and commissioning
The proportional hydraulic control is constructed in its entirity.
The signal generators are to be positioned where you think most suitable.
When constructing the relay sequencer control, the respective step can
for instance be checked for its set and reset function by means of a
manual signal triggering. With the help of the sequence table, it is also
possible to easily check the output signals for each step. These must
correspond to the bit code for the polling of setpoint values and are displayed by light emitting diodes at inputs I1 to I3 of the amplifier card.
The setpoint values are set approximately in accordance with the designated speeds (e.g.rapid traverse / creep speed). For example, if the
highest possible speed is required, a setpoint value of 10 volts is set.
It is recommended to start with the ramp setting zero.
It is of course possible to set the values specified in the solution direct.
After this, the first cycle is started and the sequence observed.
The sequential process is optimised by adapting the cylinder speeds,
acceleration and deceleration ramps, as well as the positions of the signal generators.
For fine-tuning, the basic and jump current are also of importance. This
is described in detail in the preface.
Visually, the motion sequence is to be represented in accordance with
the specified displacement-time diagram.
C-32
Solution 4
Setting operation
At simple setting operation can be carried out at the end of any cycle
with the selector switch AUTOMATIC/ RESET, whereby the last sequence stage is no longer set or reset. The setpoint value W1 with the
signal polling code 0/0/0 becomes active. The proportional solenoids
1Y1 and 1Y2 can now be manually actuated with and the hydraulic cylinder delicately traversed and positioned.
A changeover in AUTOMATIC mode and setting of the last control stage
is only enabled by 1B1 in the initial position.
Conclusion
The optimisation of the sequence motion of an installed proportional

hydraulic system is effected by the interaction of the following measures:
Harmonization of
Amplifier card
Positioning of the signal generators.

Setting of the setpoint values.
Setting of the ramps.
Fine-tuning of the amplifier.
Selector switch
Display
FUNCTION
2-channel amplifier
IA BASIC
IA JUMP
50 mA
IA MAX
800 mA
IB BASIC
IB JUMP
50 mA
IB MAX
800 mA
DITHERFREQ
200 Hz
C-33
Solution 4
Item
Description
Pressure filter
Pressure gauge
Hose
Item
Description
Power supply unit
Setpoint value card
Main switch
Push button Set
Limit switch
10
Time relay, with switch-on delay
Set of cables
C-34
Solution 4
C-35
Solution 5
Hydraulic lift
Fig. 5/1:
C-36
Solution 5
Fig. 5/2:
Signal generator in
positioning diagram
VLift
Position
Creep speed
Creep
speed
Displacement
VLower
C-37
Solution 5
Sequence table
Setpoint value
polling
+ 1Y1
- 1Y2
I1
I2
I3
Amplifier
output
Step
Sequence
Setting
operation
Advancing/
retracting with
optional stops
Acceleration
to stroke
speed
Push button
Lift
W2
+ 10 V
R1
0.05 S/1 V
Deceleration
to creep
speed
1S1
W3
+3V
R2
0.05 S/1 V
Positioning
1S2
W1
0V
Acceleration
to lowering
speed
Push button
Lower
W4
- 10 V
R3
0.05 S/1 V
Deceleration
to creep
speed II
1B3
W5
-3V
R4
0.05 S/1 V
Deceleration
to creep
speed I
1B2
W6
-1V
R4
Positioning
Signal
generator
Setpoint
value
Selector
switch
AUTO/SET
1B1
W8
0 bis +10 V
0 bis - 10 V
W1
0V
Ramp
Set to
zero
OA
A
OA
B
1Y3
Comment
Commissioning
Lift
Lower
Corresponds to
the initial
position for
lifting
C-38
Solution 5
Fig. 5/3:
LIFT
Start
Lift
LOWER
Start
Lower
C-39
Solution 5
Fig. 5/4:
Separate energy source
Set
Lift
Lower
AUTO/
SET.
C-40
Solution 5
General information regarding interrupt positioning

Interrupt positioning is widely used in hydraulic drive technology. The
signal generator approached via rapid traverse/creep speed, emits a
signal for the positioning of the drive by means of poppet non-return
valves.
A certain time interval is involved from the response time of the signal
generator to the completed closing process of the poppet valve and the
stopping of the hydraulic drive, which results in the overtravelling of the
signal generator.
A favourable solution is a signal control with short, constant switching
times, such as that provided by a relay control. In the case of a PLC
controller, the cycle time is unfavourable; therefore, an appropriate programming method is used.
The closing process of the piloted poppet valves must be quick, i.e. a
4/3-way proportional valve with mid-position working lines to tank return is suitable as a final control element.
The overtravelling distance up to switch-off is to be taken into account
when adjusting the signal generator during commissioning.
C-41
Solution 5
Our example:
For the practical assembly, the 4/3-way proportional valve with midposition closed contained in the equipment set is used.
When the position indicator is reached, the amplifier output is switched
off and the 4/3-way proportional valve moves directly into the midposition the cylinder is in position.
With Festo Didactic control technology, it is possible to close the outputs
for the valve control signals to inputs OA A and OA B by means of a
control signal (24 V).
A relay sequencer in the form of a permanent control system for the
sequence of rapid traverse/creep speed/position is feasible. The setting
of a stage by means of the corresponding signal generator means:
Output signals for setpoint value polling.

Preparation of next stage.
All stages remain set up to the last stage. In this exercise, the last stage
does not need to remain stored, since it resets the first stage, which in
turn resets the next stage until the sequencer has been completely reset.
With the reaching of a position, the entire sequencer is reset and with
the releasing of the first stage, the corresponding amplifier output is
switched off. This is the normally closed contact K1.1 in current path 25
for lifting and the normally closed contact K4.1 in current path 26 for
lowering. In the respective positions, the setpoint value W1 is selected
via the polling code 0/0/0.
W1 is set to 0 volt, thereby permitting acceleration in both directions
without initial retardation as soon as lift or lower is pressed.
C-42
Solution 5
Piloted non-return valve and proportional directional control valve

When connecting these two devices together, faultfree opening and
closing must be ensured for the specified time period.
Interference of the closing function
Use of a 4/3-way proportional directional control valve with mid-position
closed does not provide correct relieving for a clean closing of the nonreturn valve. Moreover, this results in leakage loss towards the two
working lines, which are consequently put under pressure a non-return
valve could be opened/activated. In the case of our example, this has
been ignored, since this would necessitate additional proportional directional control valves in equipment set TP702.
Fig. 5/5:
Actuation using a
C-43
Solution 5
Interference of activation function

Proportional directional control valves are direction and flow control
valves. Flow is controlled in both working lines, whereby pressure is
available both between the proportional directional control valve and the
cylinder the activating function may be impeded during the positioning
operation.
Remedy:
a) Use of a piloted non-return valve with oil return port.
Fig. 5/6:
b) Separate activation by means of a solenoid directional control valve.

Fig. 5/7:
C-44
Solution 5
Control edge geometry

As can be seen from the travel diagram, acceleration and deceleration is
irregular. This is due to the progressive characteristic flow curve of the
valve. This is created by means of a corresponding control edge geometry of the valve piston. With this, the cross section of the opening is
within the control edge geometry.
Below are examples of valve pistons for various drive acceleration patterns.
Fig. 5/8:
Spool with varying
control edge geometry
Lowering speed
As a rule, a higher lowering speed is designated in relation to the lifting
speed for hydraulic lifts. In this example, deceleration takes place in two
creep speed stages, whereby the last stage has a very low value to prevent hard impact on stopping.
C-45
Solution 5
Setting operation
For the setting operation, the sequencer is reset in all situations by
means of disconnection from supply and manual travel operation, facilitated with setpoint value W8 for setting in both positions. If the setpoint
value W8 is at 0 volts, the lift remains stationary.
The setting operation is of advantage if, for instance, the travel command continue is given from the upper position. The lift will of course
start, but will then be stopped by the cylinder end position. The same
also applies for the opposite direction.
As a result of the setting operation and thus the resetting of the sequencer, the latching of the travelling commands Lift and Lower is
also cancelled, whereby a new travel command can be input.
Note for practical assembly on the training unit
In order to also obtain a good representation of positioning optically, we
recommend that the signal generators are placed as below.
Fig. 5/9:
Positional sketch
for signal generators
Stoke
General information regarding hydraulic lifts

The lowering process is effected without a pump, purely by means of
the potential energy of the load. The acceleration and deceleration process as well as the lifting and lowering process must be constant and
independent of the load. This is why a pressure balance is used for a
constant differential pressure over the cross section opening of the
valve. See also workbook TP701, exercise 10.
In the case of control technology concepts for lifts, a setpoint value
curve is polled for start-up and deceleration and travelled via closed loop
control. See also the Festo Didactic training package TP511, Fundamentals of closed-loop hydraulic control.
C-46
Solution 5
Safety regulations and parameters

The same applies for the hydraulic lift exercise as with other exercises,
i.e. due to the extent of the safety requirements, these have not been
fully taken into consideration.
Conclusion
Switching time and stop position

The switching time of the signal control affects the stop position in general. The switching time extends from the response time of the signal
generator through to the completed switching process of the hydraulic
final control elements. The signal generator is therefore overtravelled by
a corresponding distance.
An effective means is a relay control system with short, constant
switching times. The switching time is to be taken into account when
adjusting the signal generator during commissioning.
Harmonization of
Amplifier card
Selector switch
Display
FUNCTION
2-channel amplifier
IA BASIC
IA JUMP
50 mA
IA MAX
800 mA
IB BASIC
IB JUMP
50 mA
IB MAX
800 mA
DITHERFREQ
200 Hz
C-47
Solution 5
Item
Description
Pressure filter
Pressure gauge
Hose
Item
Description
Power supply unit
Setpoint value card
Switch AUTO/SET
Push button Set
Limit switch
10
Set of cables
C-48
Solution 5
C-49
Solution 6
Drawing press
Fig. 6/1:
End position
C-50
Solution 6
Fig. 6/2:
Signal generator in
pressure-time diagram
Pressure pProp.DBV
Drawing
stroke
Sec.
Drawing operation
Time t
Return stroke
Sequence table
Setpoint
value
Step
Sequence
Setpoint value
polling
+ 0Y
I1
I2
I3
Ramp
1Y
Start button
W1
10 V
50 bar
R1
0.05 S /1 V
1S
W2
4.5 V
25 bar
R2
0
Signal
generator
Acceleration for
advancing and
drawing action
Preparing return
stroke
Start Time function
Acceleration for
return stroke
Time
expired
W1
R1
active
Low pressure
stage for smooth
retracting
1B2
W3
3V
17 bar
R2
0
Initial position
1B1
W3
Comment
C-51
Solution 6
Fig. 6/3:
Start
C-52
Solution 6
Fig. 6/4:
General information regarding acceleration of hydraulic drives

Optimum settings of the starting and decelerating behaviour of a hydraulic drive can be achieved by means of the ramp function of the control electronics.
In some cases, proportional pressure valves may also be used to
achieve the acceleration for the drive. However, prior to the acceleration
phase, the setpoint value and as such the pressure setting must be reduced and then accelerated by means of the ramp. In the acceleration
phase, the proportional pressure relief valve closes continually; the
volumetric flow range increases in accordance with the drive.
It is of course not always possible to lower the pressure prior to such a
process step, so that this type of solution is the exception rather than
the rule.
C-53
Solution 6
Regarding this example

A low pressure stage is switched in the initial position by means of setpoint value 3 and the drive maintained in the upper position. After the
start, the drawing tool is applied to the sheet metal whilst still at a low
pressure and then forms the sheet with increasing force. The setpoint
value 1 moves to its value via ramp R1 to its value.
A conventional pressure relief valve is switched as a counter pressure
during the entire drawing operation. This is a technical requirement for
the starting and overrun distance. In this exercise, the counter pressure
simultaneously simulates the forming resistance, whereby the acceleration can also be visibly seen.
Limit switch 1S initiates the return stroke by switching to a low pressure
stage in accordance with setpoint value 2 and the counter pressure
valve becoming a decelerating valve. Limit switch 1S simultaneously
starts a timer, which polls the setpoint value 1 on expiry of 0.1 seconds.
The return stroke is accelerated by means of the set ramp R1. A time
function is required, since the pressure value needs to be lowered before the acceleration step can be initiated via the ramp. Signal generator
1B2 polls the pressure stage for retraction into the initial position.
A one-way flow control valve has been connected in the exhaust for load
simulation. This flow control valve and the counter pressure for the forward stroke are to be set in such a way that the acceleration and deceleration phases are visible.
Prior to the acceleration phase by means of a proportional pressure relief valve, it must be possible to lower the setpoint value and as such the
pressure value in the system.
Selector switch
Display
FUNCTION
1-channel amplifier
IA BASIC
60 mA
IA JUMP
0 mA
IA MAX
500 mA
IB BASIC
IB JUMP
IB MAX
DITHERFREQ
200 Hz
Conclusion
Harmonization of
Amplifier card
C-54
Solution 6
Item
Description
Pressure filter
4/2-way solenoid switching valve
Non-return valve
Tee
Pressure gauge
Hose
Item
Description
Power supply unit
Setpoint value card
Main switch
Start push button
Limit switch
Set of cables
C-55
Solution 7
Honing machine
Fig. 7/1:
C-56
Solution 7
Fig. 7/2:
Signal generator in
Displacement
Standart and short-stroke honing within overall stoke range
Strokerange
Time
C-57
Solution 7
Sequence table
Setpoint
value
Setpoint value
polling
Signal
generator
+ 1Y1
- 1Y2
I1
Selector
Advancing/
retracting with switch
optional stops AUTO/SET
W8
0 to+ 10 V
0 to- 10 V
Set to
zero
Automatic
1
S1
Approach and and
honing start
A1
W2
0 to+ 10 V
Ramp setting zero

R1 0 to
possible. A1 threshold value
0.05 V/1S infinitely adjustable.
2, 4...
Honing
return stroke
B1
W3
0 to- 10 V
R2 0 to
R3 0.05
V/1S
Ramp setting zero

possible. B1 threshold value
infinitely adjustable.
3, 5...
Honing
forward
stroke
A1
W2
R4 0 to
R1 0.05
V/1S
Ramp setting zero

possible. A2 threshold value
infinitely adjustable.
Continuous
operation
STOP
S2 without
time funct.
without incorrect thresh.
value
W3
R2
R3
Initiation of return stroke up

to initial position..
n+1
Soft stop
A1
W1
0V
R4
Decelerate to standstill
in initial position.
n+2
Initial position
without
sensing
W1
Step
Setting
operation
Sequence
I2
I3
Ramp
Comment
Reversing in setting
operation is possible only in
the initial position.
Cylinder pressurised in
initial position,
see hydr. circuit diagram.
C-58
Solution 7
Fig. 7/3:
AUTO/
SET.
AUTO/SET
Threshold value generator
Time
function
Continuous
operation
signal latch
C-59
Solution 7
Fig. 7/4:
SET
Continuous
operation
Continuous
operation
Forward
stroke
Return
stroke
Threshold
value
setting
not
permitted
C-60
Solution 7
Hydraulic power section

An ideal solution possibility is the bypass circuit using the 4/3-way proportional valve, which is connected in the form of a 3/3-way proportional
valve. During the forward stroke, the drive is held by means of the bypass circuit. During the return stroke, optimum holding is effected by
means of the flow control action of the proportional valve.
When the hydraulic pump is switched off, a counter-pressure valve
based on a poppet principle keeps the drive leakage-oil free in the initial
position. The counter pressure can be set low in this exercise.
Signal control
The function and connection of the linear potentiometer and the comparator card has been explained in exercise 3 and is a prerequisite for
this exercise. The hysteresis is to be set to zero, so that all threshold
value generators A1, A2 and B1 supply the set setpoint value as threshold value.
As far as the required sequence is concerned, all that is needed is a
simple continuous operation between the threshold values A2 and B1,
whereby the initial position is to be approached. The initial position is
defined by means of the threshold value setting A1. For a position message, A1 must be below the required threshold value.
Current paths 10 and 11 form the signal latching for continuous operation, which is triggered by means of three possibilities: Push button, time
function or a non permissible threshold value setting for A2 and B1. If a
threshold value B1 is selected in error, which is smaller than A2, then
continuous operation will be stopped current path 17.
With any stop during continuous operation, the cylinder travels across
the retracted honing position into the initial position. From the retracted
honing point, current path 14 assumes the voltage supply to generate
the return stroke signals. As soon as the threshold value for the initial
position fails to be met, current path 14 is interrupted by K4. The drive is
decelerated to standstill or moves into the end position, depending on
the setting of threshold value A1.
C-61
Solution 7
Commissioning
During commissioning, it can be seen that without ramp settings a relatively smooth reversing action is achieved, thereby ensuring an efficient
honing process.
With ramp settings, the reversing action becomes very smooth which, of
course, also results in correspondly longer reversing path. At the point
of reversal, the switching of the setpoint value is cancelled via the ramp
and, at the same time, the connected setpoint value in the reverse direction is accelerated via the ramp.
The smallest possible stroke can be established in the test:
Threshold values A2 and B1 are brought closer to one another, so that
finally, the smallest possible switching time is active between forward
and return stroke. The stroke is now determined strictly by the drive
speed set.
If the proportional valve with amplifier is adapted to the volumetric flow
rate, this results in a high I MAX value, since a high volumetric flow rate
is also created during advancing via the bypass circuit. Harmonization
can for instance be effected during the oscillating movement by changing I MAX, whilst observing the cylinder speed. The honing speed is
reduced with a certain value slightly less than the maximum possible
deflection of the control piston. I MAX should be slightly above this.
As a rule, the honing stroke speed setting is the same for both directions. In our solution, various speeds can be set for special cases by
means of two setpoint value generators.
Setting operation
The setting operation can be selected in the initial position using the
selector switch AUTO/SET. With this, current paths 6 to 17 become deenergised and the setpoint value W8 of the setpoint value card become
active.
Precision movement of the drive is possible in both directions.
A reversal to automatic is also only possible in the initial position.
By means of corresponding ramp settings, it is possible to create a

smooth reversing action. At the point of reversal, the switched off setpoint value is cancelled via the ramp and at the same time the connected setpoint value in the reverse direction is accelerated via the
ramp.
Conclusion
C-62
Solution 7
Harmonization of
Amplifier card
Item
Description
Pressure filter
Counter-pressure valve (DBV)
Non-return valve
Tee
Pressure gauge
Hose
Item
Description
Power supply unit
Setpoint value card
Comparator card
Push button Start and Stop
Switch Auto/Set
11
Set of cables
Selector switch
Display
FUNCTION
2-channel amplifier
IA BASIC
50 mA
IA JUMP
100 mA
IA MAX
100 mA
IB BASIC
50 mA
IB JUMP
70 mA
IB MAX
100 mA
DITHERFREQ
200 Hz
C-63
Solution 8

Fig. 8/1:
C-64
Solution 8
Fig. 8/2:
Signal generator in
V-t-diagram
Speed
(m/s)
Mould
closed
Mould
open
Close
Open
Time
(s)
Closing time
C-65
Solution 8
Sequence table
Setpoint
value
Step
Sequence
Signal
generator
+ 1Y1
- 1Y2
Setpoint value
polling
I1
Ramp
R1
0 (0.05)
V/1S
W4
-8V
1B2
Deceleration
in end position
Initial position
W2
+ 10 V
Deceleration to
closing speed
High closing
force
1S1
W3
+3V
Holding of
closed mould
1S2
W3
remains
active
Acceleration
to opening
speed
Time
expired
Deceleration
to creep
speed
I3
Acceleration
to high
closing speed
Start button
I2
1Y3
Comment
Bypass circuit active
R2
0.05 V/1S
Bypass circuit passive

- entire piston surface
available for force
R3
0.05 V/1S
W5
2.5 V
R4
0.05 V/1S
1B1
W1
0.1 V
R4
active
without
sensing
W1
remains
active
Start of time function

for injection moulding
process
Retracted end position

without monitoring
C-66
Solution 8
Fig. 8/3:
C-67
Solution 8
Fig. 8/4:
Separate
energy source
C-68
Solution 8
General information regarding bypass circuit

In hydraulic control technology, a bypass circuit for cylinders provides an
optimum solution, if increased advancing speeds are required and the
dimensions of the cylinder are adequate for the designated force required. Preferably, a cylinder with a surface ratio of 2:1 is to be used.
However, the system also functions without any problem with the surface ratio of 1.64:1 of the cylinder contained in this Festo Didactic training package for proportional hydraulics. Naturally, the increase in speed
is correspondingly lower and the potential force less.
The bypass circuit for rapid traverse movements is also utilised in proportional hydraulics.
In this example:
The bypass circuit for rapid traverse is achieved by means of a 4/2-way
solenoid switching valve, which is connected in the form of a switching
gate. The bypass can be switched by means of a 24 V signal.
Initial position by means of soft stop
The initial position must be accurately defined in accordance with the
designated solution. In this example, the initial position is reached by
switching to a creep speed by means of B B1 via ramp R4. A so-called
soft stop, whose position is not sensed any further.
However, a minimum setpoint value should remain switched (W1=
- 0.1 V), in order to achieve the jump function and to prevent an uncontrolled movement at creep speed in the initial position. A correspondingly high basic and jump current for the return stroke side prevents
cylinder creep.
It is of course possible to work with a very high basic current on only one
side with setpoint value W1= 0 V, in order to keep the cylinder in the
retracted end position. However, the behaviour during the approach is
less favourable. Try out the above.
C-69
Solution 8
Behaviour of controller during start

Setpoint value W2 and the bypass are switched simultaneously via the
start signal.
The pre-pressurised volume in the cylinder piston chamber immediately
acts on the piston and accelerates this in jumps, since the cylinder is not
loaded.
If ramp R1= 0 is set, then the jump does not take place, due to the effect of the volumetric flow from the proportional directional control
valves.
Switching over to high closing force
The bypass is cancelled via 1S1 and the entire piston surface thereby
released for pressure actuation. At the same time, setpoint value W3 for
reduced closing speed is polled via ramp R3.
The mould is held closed using the highest closing force. The injection
moulding process is simulated by means of a time function.
Note regarding practical assembly on the training unit
In order to also obtain a good visual representation of the closing and
opening process, it is recommended that the placing of the signal generator as specified below , be roughly maintained.
Assembly, commissioning and harmonization is to be effected in the
same way as described in exercise 1.
Fig. 8/5:
Positional sketch
for signal generators
Stroke
As a result of the bypass, a large volumetric flow is available for the

rapid traverse movement. By switching off the bypass, the entire piston
surface can be pressurised for a high closing force.
Proportional hydraulics also make use of the advantages of this connection technology.
Conclusion
C-70
Solution 8
Harmonization of
Amplifier card
Item
Description
Pressure filter
Tee
Pressure gauge
Hose
Item
Description
Power supply unit
Setpoint value card
Main switch
Push button Start
Limit switch
Set of cables
Selector switch
Display
FUNCTION
2-channel amplifier
IA BASIC
IA JUMP
50 mA
IA MAX
800 mA
IB BASIC
80 mA
IB JUMP
100 mA
IB MAX
700 mA
DITHERFREQ
200 Hz
C-71
Solution 9

Fig. 9/1:
Simulation of
plasticizing and
injection resistance
C-72
Solution 9
Fig. 9/2:
Signal generator
in diagram
rpm
-1
Speed and pressure characteristics
Motor
Time (s)
bar
Cylinder
Counter pressure
during plasticising
process
Injecting
Granulate
filling
time
Time (s)
new
cycle
Consolidating pressure
C-73
Solution 9
Sequence table
Proportional-Flow control valve

sequence
Step-No.
Setpoint
value
Sequence
1Y1

I1
I2
I3
Ramp
1Y3
Comment
Accel. motor to n1
W2
3.5 V
R1
0.05 V/1S
Start button S1
Accel. motor to n2
W3
7.5 V
R1
Clock pulse K7
3 - 4 sec.
Decelerate motor
to standstill
W4
0V
R2
0.80 V/1s
Clock pulse K8
5 - 6 sec.
Accel. inj. cylinder

to V1
W5
4.5 V
R1
Clock pulse K7
Accel. inj. cylinder to

V2
W6
10 V
R1
B1
Cylinder advanced
W1
3.0 V
B2
6
Initial pos.
Sequence table
Proportional- Pressure relief valve

sequence
Step-No.
Sequence
Setpoint
value
1Y1

I1
I2
I3
Ramp
1Y3
Comment
Counter pressure
32 bar
W2
5.2 V
R2
0.05 V/1S
Start button S1
Counter pressure
20 bar
W3
3.9 V
R2
Clock pulse K7
3 - 4 sec.
Counter pressure
30 bar
W4
4.8 V
R1
0.05 V/1S
Clock pulse K8
5 - 6 sec.
Injecting pressure to
45 bar
W5
8.5 V
R1
Clock pulse K7
Injecting pressure to
57 bar
W6
9.0 V
R1
B1
Counter pressure
40 bar
W1
6.2 V
B2
6
Initial pos.
The steps 1-6 for the proportional flow control valve and the proportional
pressure relieve valve are executed parallel. Please refer to signal
branching on page C-79.
Note
C-74
Solution 9
Fig. 9/3:
C-75
Solution 9
Fig. 9/4:
Separate
energy source
C-76
Solution 9
General information regarding speed control systems of several

hydraulic drives using a proportional flow control valve
If a speed control systems is required for just one hydraulic drive within
an individual process step, then the entire speed control can be assumed by a single proportional flow control valve. Fewer control units
mean reduced investment expenditure and generally also a reduction in
repair costs.
Regarding this example:
The above described speed control system can be used for the designated injection moulding process. For this, the 4/3-way proportional
valve is connected in the form of a 2/2-way proportional flow control
valve.
The plasticising and injection moulding process is time controlled, the
consolidating pressure is stroke-dependent.
As can be seen from the sequence table, the same setpoint value allocation is made for the two setpoint value cards in the individual process
step. This minimises the electrical signal control. The setpoint value inputs are simply switched in parallel.
Throughout the entire process, the plasticising and injection resistance
is simulated onto the cylinder annular surface by means of the pump
output pressure, whereby the injection moulding process can be very
realistically demonstrated.
The counter pressures for the injecting cylinders must be set in such a
way that the cylinder is pushed back during the plasticising process,
reaching the retracted end position roughly when the motor comes to
rest. This can be further optimised by means of an individual clock-pulse
setting, whereby clock-pulses 1 and 3 are identical. The injection
moulding starts on expiry of the third clock pulse. The consolidating
pressure is applied via a position indicator.
The clock pulses are roughly within a range of 3 to 6 seconds.
As can be seen from the sequence table, switching takes place from
setpoint value 6 to setpoint value 1 for the proportional flow control valve
at the end of the cycle. With this, the setpoint value operates via ramp
R2 from 10 volts to 3 volts. A restart should therefore not take place
before the ramp time has expired, since a high speed value n1 could be
immediately implemented. In practice, this would of course be the filling
time for the granular material.
C-77
Solution 9
If a high speed control is required for just one hydraulic drive within an
individual process step, then the entire speed control for all drives can
be assured by an individual proportional flow control valve.
Valve
Proportional flow
control valve
Proportional pressure
relief valve
Selector switch
Display
FUNCTION
2-channel amplifier
IA BASIC
50 mA
IA JUMP
80 mA
IA MAX
800 mA
IB BASIC
50 mA
IB JUMP
IB MAX
750 mA
DITHERFREQ
250 Hz
Conclusion
Harmonization of
Amplifier card
C-78
Solution 9
Item
Description
Pressure filter
Hydromotor
4/3-way proportional valve in the form of 2/2-way proportional

flow control valve
Non-return valve
Tee
Pressure gauge
10
Hose
Item
Description
Power supply unit
Setpoint value card
Main switch
Push button Start
10
Time relay, with switch-off delay
Set of cables
C-79
Solution 10
Injection moulding machine with mould closing device
Installation de-energised
Mould open
Mould closing process
Mould closed
Plasticising an injecting process
Plasticising an injecting
process completed
Mould closing process
Fig. 10/1:
Function chart
C-80
Solution 10
Fig. 10/2:
Signal control system,
electrical
Deactivation
Deactivation
C-81
Solution 10
Fig. 10/3:
overall installation
C-82
Solution 10
Objective
Two separate projects are to be combined into one, although this may
still comprise two separate hydraulic training workstations.
For instance, the exercises mould closing device and injection
moulding machine are to be designed, constructed and commissioned
individually on the training workstations 1 and 2 respectively.
The individual systems can then be linked together into one overall
system to include all groups.
Apart from the extended group work, it is also possible to represent a
relatively more complex overall process.
The necessary signal interface is simple and can be easily implemented
in the form of a modification or adaptation.
Overall project from the outset
From the outset, this same exercise can also be carried out as an overall project. A complete hydraulic circuit diagram is contained in this exercise for this purpose.
No overall electrical circuit diagram has been drawn up as a solution
since, ideally, individual electrical circuit diagrams of the mould closing
unit and injection moulding machine are to be used. This results in a
systematic and reliable assembly and permits the testing and commissioning of the individual processes.
Only then is the interface logic operation to be integrated. This subsequent logic operation of two individual processes is one of the training
aims formulated in this exercise. The interface logic operation is drawn
by a dashed line in the electrical circuit diagram.
The function chart as specified in DIN 40719 / 6 (IEC 848)
The function chart is a process-oriented representation of a control task,
irrespective of the technical realisation.
A function chart facilitates the precise recording and description of a
control task.
C-83
Solution 10
As can be seen from exercise 10, it is an advantage to first of all structure and represent the required overall process irrespective of technology.
Conclusion
Generally, and in particular in the case of proportional hydraulic problem

descriptions, this can be easily solved by means of a function diagram.
Item
Description
Pressure filter
Hydraulic motor
Non-return valve
Tee
Pressure gauge
16
Hose
Item
Description
Power supply unit
Setpoint value card
Main switch (latching switch)
Push button Start
Limit switch
19
Time relay, with switch-off delay
Set of cables


C-84
Solution 10
Equivalent circuits
Circuit diagram with 2/2-way

proportional valve and 4/2way proportional valve
Description
Circuit diagram with

2/2-way proportional
valve connected into
the supply flow.
No counter pressure
exists.
the supply flow.
Counter pressure
exists as result of
adjusted flow control
apperture ratio.
PA:BT=1:1
the supply flow with
double flow rate.
both cross sections of
flow P A and B T
are utilised for increased flow rate.
Without counter pressure.

Festo-Proportional Hydraulics Advanced Level

Uploaded by

Copyright:

Available Formats

Festo-Proportional Hydraulics Advanced Level

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Festo-Proportional Hydraulics Advanced Level

Uploaded by

Copyright:

Available Formats

What are the different types of training packages described?

What are the different types of training packages described?

What are the components of the learning system?

What are the components of the learning system?

Learning System for Automation

Authorised applications and liability

Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 1999

TP702 Festo Didactic

Basic packages deal with basic knowledge spanning a wide range of

Technology packages deal with important areas of control technology.

Function packages explain the basic functions of automation systems.

TP702 Festo Didactic

The modular design of the learning system permits applications which

The hardware consists of industrial components and installations,

Textbooks (with exercises and examples)

Overhead transparencies and videos (to provide a lively, interactive

TP702 Festo Didactic

All electrical cables with safety plugs.

Exercises with exercise sheets and solutions, leading questions.

Practice in teamwork, cooperation, study technique, independence

Exercises and worksheets

Function diagram, circuit diagrams, solution description and components lists

Storage tray, mounting systems, coupling

TP702 Festo Didactic

TP702 Festo Didactic

Notes on procedure regarding proportional hydraulics

Training contents of Proportional Hydraulics Advanced Level TP702 22

Equipment set Proportional hydraulics Basic level TP701

Equipment set Proportional hydraulics Adavanced level TP702

Allocation of components and exercises

Methodical structure of the exercises

TP702 Festo Didactic

Mould closing device

Injection moulding machine

Injection moulding machine with mould

Mould closing device

Injection moulding machine

Injection moulding machine with

TP702 Festo Didactic

The following are recommended for the practical implementation of the

Hydraulic and electrical components of equipment sets TP701 and

A hydraulic power pack

TP702 Festo Didactic

Plotting of characteristic curves of various sensors.

The technical prerequisites for the safe operation of components are:

A hydraulic power pack for an operating pressure of 60 bar and

A voltage supply of 230 V AC for the power pack.

TP702 Festo Didactic

Caution! Cylinders may advance as soon as the hydraulic power is

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

TP702 Festo Didactic

The maximum permissible pressure for all hydraulic components is

In the case of double-acting cylinders, an increase in pressure may

If the connections are released under pressure, pressure is locked

All valves, equipment and hoses have self-sealing couplings. These

TP702 Festo Didactic

Notes on procedure regarding

TP702 Festo Didactic

Owing to the particular mode of operation of continuous adjustability of