Learning System for Automation and Communications

Electrohydraulics

Set of Overhead Transparencies

Basic Level D.OT-TP601-GB 095051

Order no.: Designation: Description: Edition: Graphics: Layout: Author:

095051 E.-HYDR. FOLIEN D.OT-TP601-GB 2/96 T. Ocker, D. Schwarzenberger 23.2.96, M. Schwarz D. Scholz

Copyright by Festo Didactic KG, D-73734 Esslingen, 1996 All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, or otherwise, without the prior written permission of Festo Didactic KG.

Festo Didactic

601

This set of overhead transparencies has been designed for use with the basic level of the technology package TP600 Electrohydraulics. The set of overhead transparencies and the technology package form part of Festo Didactic KGs Learning System for Automation and Communications. The 30 transparencies in this set have been optimised from the didactic and methodological points of view. Each transparency is accompanied by a short text which provides the trainer with a quick overview of the training contents of the transparency concerned. Training contents:

Introduction

Basic principles of electrohydraulics Function and use of electrohydraulic components Basic principles of electrical engineering Production and interpretation of standard hydraulic and electrical circuit diagrams

The text sheet includes a complete illustration of the transparency, in certain cases with additional explanations and legends which the trainer can enter on the transparency in the course of a training session. The advantages of this concept are:

The trainer can add to the transparencies step by step in the course of a training session. The trainer is thus able to create a lively and interesting atmosphere. The provision of accompanying text means less preparation work for the trainer.

601

Festo Didactic

Contents

Electrohydraulic press . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 1 Schematic layout of an electrohydraulic installation . . Transparency 2 Electrical power supply unit . . . . . . . . . . . . . . . . . . . . . Transparency 3 Electrical circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 4 Measuring circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 5 Ohms law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 6 Rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 7 Analogue, digital and binary . . . . . . . . . . . . . . . . . . . . . Transparency 8 Momentary and sustained contact switches . . . . . . . . Transparency 9 N/O, N/C and changeover contacts . . . . . . . . . . . . . . Transparency 10 Limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 11 Proximity switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 12 Solenoid (electromagnet) . . . . . . . . . . . . . . . . . . . . . . . Transparency 13 Electrohydraulic converters (solenoid valves) . . . . . . . Transparency 14 Dry and wet solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 15 Solenoid valve connections . . . . . . . . . . . . . . . . . . . . . . Transparency 16 Relays and contactors . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 17 Direct and indirect activation . . . . . . . . . . . . . . . . . . . . Transparency 18 Signal inversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 19 Latching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 20 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 21 Hydraulic power pack . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 22 Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 23 Electrical and hydraulic power . . . . . . . . . . . . . . . . . . . Transparency 24 Power losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 25 Pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 26 4/3-way solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 27 4/3-way solenoid valve, piloted . . . . . . . . . . . . . . . . . . Transparency 28 Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 29 Hydraulic safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 30

Electrohydraulics

Festo Didactic

Title Notes

Electrohydraulic press

Function units: Motor with hydraulic pump, control panel, valve manifold, cylinder. The hydraulic press is controlled via the electrical control panel. Electrical signals are used to activate the valves in the hydraulic installation. The electrohydraulic press is used to form rectangular troughs.

Motor with hydraulic pump

Valve manifold

Actuator (cylinder)

Control panel

601-01-GB

Electrohydraulics

Festo Didactic

Title Notes

Schematic layout of an electrohydraulic installation

Division of installation into signal control section and hydraulic power section. Signal control section: Input and processing of electrical signals. Solenoid valves form the interface between the electrical signal control section and the hydraulic power section. Hydraulic power section: Controls the flow of hydraulic fluid by means of solenoid valves. Actuators convert hydraulic energy into motions.

Power section Signal control section

Hydraulic cylinder

Signal input

Signal processing

Solenoid valve

Power supply

Hydraulic power supply (conversion)

601-02-GB

Electrohydraulics

Festo Didactic

Title Notes

Electrical power supply unit

Connection to mains supply. Supplies signal control section with specified or maximum voltage and current values. Functions in power supply unit: Voltage transformation, rectification, smoothing, stabilisation, fuse protection. In mobile hydraulic systems, rechargeable battery systems or generators are used as a power supply for the signal control section.

230V AC DC 24V

50 C

TR Transformer

G Rectifier

T Smoothing Stabilisation

T Fuse

601-03-GB

Electrohydraulics

Festo Didactic

Title Notes

Electrical circuit

A circuit consists of at least a power source, a load device and connecting lines. Electrical current will flow only in a closed circuit. Technical direction of current flow: From the positive terminal of the power supply to the negative terminal. A: Closed circuit without power supply. B: Introduction of a power supply to complete the circuit.

+ -

601-04-GB

Electrohydraulics

Festo Didactic

Title Notes

Measuring circuits

Voltage and current measurements. The voltage drop across a load device is measured in parallel with the device. Electrical current is measured in series.

+ V

+ A

Voltage measurement

Current measurement

601-05-GB

Electrohydraulics

Festo Didactic

Title Notes

Ohms law

Ohms law: Describes the relationship between current (I), voltage (V) and resistance (R). With ohmic resistances, the current rises in linear proportion to the voltage. Graph: The value pairs for a constant resistance lie on a straight line. The current I is proportional to the voltage V. Mathematical formula for Ohms law: V = R I or I = V / R.

Resistance R Relay Solenoid coil V=RI I= V R

10 V 0.5 A

20 V 1A

30 V 1.5 A 1A

40 V 2A 1.33 A

0.33 A 0.66 A

A + R V
I

2.0 A 1.5 1.0 0.5 0 0 10 V 20 30 V 40

601-06-GB

Electrohydraulics

Festo Didactic

Title Notes

Rectifiers

Rectifiers convert AC to DC. Diodes are conductive in only one direction. The polarity of the negative half-wave of the alternating voltage is reversed. The pulsating voltage is smoothed using a capacitor and filters (reactance coil, resistor).

~
Diodes C R =

Voltage retification

Voltage smoothing

601-07-GB

Electrohydraulics

Festo Didactic

Title Notes

Analogue, digital and binary

Analogue values describe continuous functions, such as the continuous filling of a bucket of water. Digital values describe integer parts of a maximum value. A dice, for example, shows one of six possible numbers. Binary values are a special form of digital values. They can assume only two values, such as in the case of a switch, which can only be on or off.

+ -

Volume V

full

Value

empty

Light

halffull

6 5 4 3 2 1 0

On 1

Off 0

Filling time t

Experiments with dice

Switching time point

Time t

601-08-GB

Electrohydraulics

Festo Didactic

Title Notes

Momentary and sustained contact switches

Actuation of contacts. A momentary contact switch has a rest position and an actuated position. A sustained contact switch has two detents. It thus has two rest positions. Momentary and sustained switches can close or open current paths or switch from one current path to another.

3 4

3 4

601-09-GB

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Electrohydraulics

Festo Didactic

Title Notes

N/O, N/C and changeover contacts

Example: Momentary-contact switch. N/O: Contact normally open in rest position Changeover contact: N/O and N/C contacts in a single housing; one contact is open while the other is closed. The designations of the switch contacts are governed by the European standard EN 50012.

Switch elements

Connection (N/O contact)

3 4

1 2

4 1

Connection (N/C contact)

601-10-GB

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Electrohydraulics

Festo Didactic

Title Notes

Limit switches

Determining the position of a positioning slide. Electrical contacts are actuated when a defined intermediate or end position is reached. Limit switches can be connected up as N/O, N/C or changeover contacts.

Switch lever Stem (insulated)

Contact

Snap-action mechanism

601-11-GB

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Electrohydraulics

Festo Didactic

Title Notes

Proximity switches

Inductive: Signal is generated by the presence of any material with good conductivity in an oscillating magnetic field. Capacitive: Signal is also generated by all insulators with high dielectric constants in an electrical field. Optical: Signal is generated when light barriers are interrupted or when light is reflected back to an optical sensor. Reed switches: Signal is generated by magnets whose fields close the built-in contacts in the switch.

inductive

Metal

Reed switch

capacitive

Metal or Insulator

Magnet

optical

reflective component

magnetic

601-12-GB

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Electrohydraulics

Festo Didactic

Title Notes

Solenoid (electromagnet)

A magnetic field with concentric field lines is created around a conductor carrying an electrical current. A coil carrying an electrical current develops a uniform magnetic field in its axial direction due to the overlapping of field lines. By appropriate alignment of elementary magnets, an iron core can be made into a switchable electromagnet.

Field around a conductor Iron core

+ -

Coil

601-13-GB

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Electrohydraulics

Festo Didactic

Title Notes

Electrohydraulic converters (solenoid valves)

Convert electrical signals into hydraulic switching operations. The switching armature is drawn into the coil, which acts as a magnet. This produces a displacement of the actuating piston in the hydraulic 4/2-way valve.

Switching armature

4/2-way solenoid valve T A P B L

601-14-GB

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Electrohydraulics

Festo Didactic

Title Notes

Dry and wet solenoids

Dry solenoid: The solenoid is separated from the hydraulic fluid; a seal is required on the stem. Advantage of dry solenoids: Simple construction. Wet solenoid: The armature chamber of the solenoid is filled with hydraulic fluid, the solenoid operates in oil. Advantages of wet solenoid: Low friction, little abrasion, good heat dissipation, long service life.

seal

Dry solenoid

Wet solenoid

601-15-GB

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Electrohydraulics

Festo Didactic

Title Notes

Solenoid valve connections

Connector components: Solenoid with plug base, cable with connector socket. Electrical signals are transmitted via standard connectors. Advantage: Reliable alignment of connections which can be attached and detached quickly, protected against dust and water.

2 3 1

Electrical connections Protective earth connection Plug base

601-16-GB

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Electrohydraulics

Festo Didactic

Title Notes

Relays and contactors

Definition: Switches which are actuated and held in their actuated positions electromagnetically. Used to separate control and power circuits. Special feature of relays: Hinged-armature design, single-break contacts, used for logic gating of signals, (generally) changeover contacts. Special feature of contactors: Each main contact is of double-break type (contacts used as main contacts), suitable for all power ratings from small to very large, only N/O and N/C contacts.

Coil Iron core

Armature

Contacts

+ + -

Return spring

Contacts

Return spring

Coil

Hinged-armature solenoid

Plunger-armature solenoid

601-17-GB

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Electrohydraulics

Festo Didactic

Title Notes

Direct and indirect activation

Direct activation: Connection of a solenoid valve via a switch (A). Indirect activation: Connection of a solenoid valve via a relay (B). Advantage of indirect activation: Separation of control and power circuits. The current passing through switch S1 (B) is lower, and the service life of the switch is significantly greater.

A
24V

B
24V 1 2

S1
4

S1
4

K1

Y1

K1

Y1

0V

0V

601-18-GB

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Electrohydraulics

Festo Didactic

Title Notes

Signal inversion

The output signal is inversely proportional to the input signal. A: Signal inversion at relay K1. B: Signal inversion at switch S1. The switching elements are shown under zero-voltage conditions.

A
24V 1 2 24V
1

B
1 2

S1
4

K1
2

S1
2

K1

K1

Y1

K1

Y1

0V S1 0 1 K1 0 1 Y1 1 0

0V S1 0 1 K1 1 0 Y1 1 0

601-19-GB

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Electrohydraulics

Festo Didactic

Title Notes

Latching

Latching only with indirect activation. Actuation of switch S1: Relay K1 reverses holding the current path of K1 closed. The actuation of switch S2 interrupts the latched current path.

24V

3 S1 0 0
1

S2 0 1
0

K1 & Y1 0 0
1

S1
4

K1
4 1

K1
4

S2
2

1
K1 Y1

dominant on

0V

601-20-GB

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Electrohydraulics

Festo Didactic

Title Notes

Circuit diagram

Lines of potential with constant voltage are drawn horizontally. Current paths are drawn vertically and numbered consecutively. Circuit symbols are shown in the direction of current flow. Switching elements are generally shown under zero-voltage conditions. Latching to guard against sticking of relay contacts in current paths 6 and 7.

24V

1
3

S0
4

S1

K1

S2

K2

K1

4 1

K2

4 1

K2
2 A1 A1

K1
2

K1
A2

K2
A2

Y1

Y2

0V

601-21-GB

22

Electrohydraulics

Festo Didactic

Title Notes

Hydraulic power pack

Hydraulic power pack for use in stationary hydraulic systems. Power is delivered via the pressure medium using a pump and drive motor. The pack incorporates devices to remove air, water and solid particles from the hydraulic fluid.

Pressure line Pressure relief valve (safety valve) Hydraulic pump

Return line Air filter

Filler filter Electric motor n = 1500 rpm Fluid level indicator Suction pipe Suction filter Baffle plate Drain screw Cleaning aperture

601-22-GB

23

Electrohydraulics

Festo Didactic

Title Notes

Hydraulic circuit

Hydraulic systems consist of open or closed circuits. Hydraulic fluid is used as an energy carrier. This energy is output via cylinders and motors. Relieved hydraulic fluid is returned to the tank or hydraulic pump.

Hydraulic cylinder
Electrohydraulic power valve Safety valves

Hydraulic pump Safety valve

Motor

Hydraulic motor Motor

M
Filter Return line

Hydraulic Feed pump pump (top-up for leakage losses)

open

closed

601-23-GB

24

Electrohydraulics

Festo Didactic

Title Notes

Electrical and hydraulic power

Electric motor: Driven by electric current on the basis of a potential difference. Electrical power is the product of voltage and current: P electr. = V I (unit: watts). Hydraulic motor: Driven via fluid flow on the basis of a pressure difference. Hydraulic power is the product of pressure and flow rate: P hydr. = p Q (unit: watts).

Pelectr. = V I

Phydr. = p q

Current I

Flow rate q

Voltage V

+
M

Electric motor Gear motor

601-24-GB

Pressure p

25

Electrohydraulics

Festo Didactic

Title Notes

Power losses

Efficiency of electric motors: Frictional and magnetic losses. Efficiency of hydraulic pump: Frictional and volumetric losses. Valves, piping, tubing: Pressure losses dp, power losses expressed by P = p Q. Hydraulic motors and cylinders: Frictional and volumetric losses.

Frictional and volumetric losses

Frictional and pressure losses

Frictional, volumetric and magnetic losses Phydr. loss = p lq

601-25-GB

Power losses

26

Electrohydraulics

Festo Didactic

Title Notes

Pressure switches

Actuation of electrical contacts when a defined minimum pressure is reached. The minimum pressure (switching point) can be varied by means of an adjustable spring. Example shows switching at approx. 4 bar with rising or falling pressure. Generally connected up in practice as a changeover contact.

2 3

Symbolic representation in hydraulic circuit diagram

p
1

Symbolic representation in electrical circuit diagram

1 3 2

Switching point with rising pressure

Pressure p 4 bar

Switching point with falling pressure

Hysteresis

Time t

601-26-GB

27

Electrohydraulics

Festo Didactic

Title Notes

4/3-way solenoid valve

Valve spool is directly actuated by solenoids. Actuation on left: The piston spool is displaced to the right and creates the connections P - A and B - T. Rest position produced by spring centring of piston spool. All inputs of the 4/3-way valve are closed in this position.

A
a

B
b

601-27-GB

28

Electrohydraulics

Festo Didactic

Title Notes

4/3-way solenoid valve, piloted

Direct activation of pilot spool via solenoids. Actuation on left: The pilot piston spool is displaced to the right, and hydraulic fluid is directed to the right-hand side of the main control spool, creating the connections P - A and B - T. Rest position produced by spring centring of pilot and main piston spools. All ports of the 4/3-way valve are closed at the main valve.

A P

B T

Simplified symbol

Detailed symbol

601-28-GB

29

Electrohydraulics

Festo Didactic

Title Notes

Electrical safety

EMERGENCY STOP button placed in an easily accessible position. Protection against voltages. Protection by means of insulation. Protection by means of earthed conductive housings. Safety isolation by means of transformers.

1. Switch off 2. Check 3. Carry out work EMERGENCY STOP

Safety insulation
Additional insulation

Protective earth

Safety isolation

L1
PE

220 V AC

24 V

N
Basic insulation

601-29-GB

30

Electrohydraulics

Festo Didactic

Title Notes

Hydraulic safety

Safety regulations must be observed. 1. 2. 3. 4. Switch off motor/pump. Depressurise accumulator. Lower load. Check pressure.

Work can now be carried out by authorised trained personnel.

1. Switch off motor/pump

2. Depressurise accumulator

3. Lower load

4. Check pressure

601-30-GB