Equipment set TP 501 – Basic level: Basic training in hydraulics

Training aims

Power packs and components:   Measurements and calculations:   Hydraulic circuits: * Design, function and most important characteristics of a hydraulic power unit   * Recording and interpreting the characteristic curve of a hydraulic pump   * Commissioning hydraulic circuits safely * Design and function of pressure-relief valves, cylinders and directional control valves   * Measuring the volume flow of a hydraulic control system   * Using the flow control valve in the inflow and outflow and adjusting the drive speed * Design and function of the non-return valve, one-way flow control valve and piloted non-return valve   * Recording the characteristic curve of a pressure-relief valve   * Difference between a flow control valve and one-way flow control valve in hydraulic control systems * Design and function of flow control valves   * Identifying and calculating times, pressures and forces during advancing and retracting of a cylinder   * Design and mode of operation of a differential circuit       * Recording the characteristic curve of a flow control valve   * Effect of the piston surfaces on pressures, forces, speeds and travel times       * Calculating performance ratios when using 4/3-way valves with different mid-positions   * Proper use of piloted non-return valves             * Circuits with different types of counter pressure             * Operating cylinders with varying loads

The most important components at a glance

1 Pressure relief valve   9 Shut-off valve  2 2-way flow control valve    10 Differential cylinder 16/10/200 with cover  3 One-way flow control valve    11 Weight, 9 kg, for cylinder 4 Non-return valve, delockable   12 Hydraulic motor  5 Non-return valve   13 T-distributor  6 4/2-way hand lever valve, spring return   14 4-way distributor with pressure gauge 7 4/3-way hand lever valve, relieving mid-position (AB −> T), detenting    15 Pressure gauge  8 4/3-way hand lever valve, closed mid-position, detenting    16 Flow sensor

Equipment set TP 502 – Advanced level: Hydraulics for advanced users

Training aims

Power packs and components::   Measurements and calculations:   Hydraulic circuits: * Design and function of a hydraulic motor   * Calculating performance ratios of hydraulic circuits from measured values   * Implementing bypass circuits * Setting the direction and speed of rotation of a hydraulic motor   * Calculating forces on the cylinder   * Ensuring synchronised forward and return strokes * Design, function and use of a flow divider   * Creating procedure descriptions   * Getting to know the bypass circuit * Using a hydraulic reservoir as a volume and pressure accumulator         * Getting to know the rapid traverse feed circuit * Design, function and use of a pressure regulator         * Advancing and retracting of a cylinder after the pump from the reservoir is switched off * Specifying the cylinder pressure         * Use of a hydraulic reservoir for a rapid traverse circuit * Difference between pressure-relief valves and pressure regulators         * Getting to know the rectifier circuit             * Configuration and description of a sequence control with two cylinders             * Getting to know the pressure sequence and pressure stage circuit             * Getting to know the fuse protection for tensile loads

The most important components at a glance

1 Pressure relief valve, compensated    6 Diaphragm accumulator with shut-off block  2 3-way pressure reducing valve   7 Differential cylinder 16/10/200 with cover 3 Flow dividing valve    8 Mounting kit for cylinders  4 2/2-way stem actuated valve, convertible    9 T-distributor 5 Non-return valve

Equipment set TP 601 – Basic level: Basic training in electrohydraulics

Training aims

Power packs and components::   Measurements and calculations:   Hydraulic circuits: * Design, mode of operation and areas of application of 2/2, 3/2, 4/2 and 4/3-way solenoid valves, as well as 4/2-way double solenoid valves   * Commissioning hydraulic circuits safely   * Measuring and calculating the flow in an electrohydraulic installation * Design and mode of operation of electrical pushbuttons, switches and limit switches   * Explaining and designing direct and indirect actuation   * Calculating electrical characteristic values * Design and mode of operation of a relay   * Creating and using a sequence table       * Knowing and accounting for the contact load capacity of electrical signal transmitters   * Explaining and designing signal storage in the hydraulic power section       * Selecting and using hydraulic and electrical components according to economic criteria   * Selecting solenoid valves according to the technical control requirements       * Design and mode of operation of a pressure switch   * Using and designing basic logic functions       * Knowing different ways of sensing a cylinder's end position and selecting the right one   * Explaining and designing an electric latching circuit with a dominant switch-off signal             * Designing and arranging pressure-dependent control systems             * Knowing simple operating modes and accounting for them in the circuit             * Electrically and mechanically locking of signals in a relay control system             * Expanding existing control systems and adjusting the documentation accordingly Implementing sequence control with two cylinders             * Getting to know and creating a procedure description as GRAFCET and as a function diagram             * Analysing circuits and carrying out systematic fault finding and error elimination with restart

The most important components at a glance

1 Pressure relief valve   11 Mounting kit for cylinders  2 2-way flow control valve    12 T-distributor  3 One-way flow control valve    13 4-way distributor with pressure gauge 4 Non-return valve    14 Pressure gauge  5 4/2-way solenoid valve, spring return   15 Pressure switch, electronic 6 4/3-way solenoid valve, closed mid-position    16 Relay, three-fold  7 4/2-way double solenoid valve, detenting    17 Signal input, electrical  8 Shut-off valve    18 Limit switch, electrical, left-actuated  9 Weight, 9 kg, for cylinder   19 Limit switch, electrical, right-actuated  10 Differential cylinder 16/10/200 with cover    20 Proximity sensor, electronic

Supplementary equipment set from Hydraulics

The most important components at a glance

Supplementary equipment sét from Hydraulics, Basic level TP 501 tờ Electrohydraulics, Basic level TP 601                           Supplementary equipment set from Hydraulics, Basic level TP 501 and Advanced level TP 502 to Electrohydraulics, Basic level TP 601 * Relay, three-fold    * Relay, three-fold  * Signal input, electrical   * Signal input, electrical * Limit switch, electrical, left-actuated    * Limit switch, electrical, left-actuated  * Limit switch, electrical, right-actuated   * Limit switch, electrical, right-actuated * 4/2-way double solenoid valve, detenting    * 4/2-way double solenoid valve, detenting  * 4/2-way solenoid valve, spring return   * 4/2-way solenoid valve, spring return * 4/3-way solenoid valve, closed mid-position    * 4/3-way solenoid valve, closed mid-position  * Differential cylinder 16/10/200 with cover    * Pressure switch, electronic  * Mounting kit for cylinders    * Proximity sensor, electronic  * Pressure switch, electronic        * Proximity sensor, electronic        * T-distributor

Equipment set TP 602 – Advanced level: Electrohydraulics for advanced students

Training aims

Power packs and components::   Measurements and calculations:   Measurements and calculations: (Cont) * Design and mode of operation of different proximity sensors   * Selecting proximity sensors according to the technical control requirements   * Getting to know and using further logical connections * Function and possible applications of a time relay with switch-on and switch-off delay   * Expanding electrohydraulic control systems and adjusting the documentation   * Designing and arranging pressure sequence control * Design and use of an electrical predetermining counter   * Designing and arranging path- and pressure-dependent sequence controls   * Knowing safety-related conditions that could be needed for a drive       * Identifying signal overlaps in a sequence control and taking the appropriate action   * Designing and arranging safety functions with a predefined motion sequence for a control system     * Designing and arranging sequence control as a standing sequencer   * Implementing control systems with the operating modes inching and aligning       * Using memory to implement an emergency operation   * Systematically identifying and eliminating errors in complex electrohydraulic control systems       * Implementing control systems with the operating modes single cycle and continuous cycle   * Creating sequence control as a displacement-step diagram       * Querying time in electrohydraulic control systems   * Representing procedure descriptions with GRAFCET

The most important components at a glance

1 Time relay, two-fold    7 Proximity sensor, inductive, M12 2 Relay, three-fold    8 Emergency stop pushbutton, electrical 3 Preset counter, electronic    9 T-distributor 4 Diaphragm accumulator with shut-off block    10 Non-return valve, delockable 5 Hydraulic motor    11 Pressure relief valve, compensated  6 4/3-way solenoid valve, relieving mid-position (AB −> T)

Equipment set TP 610 – Advanced level: Measurement and control in Hydraulics with FluidLab®-H

Training aims

* Basic principles of analogue processing   * Analytical fault finding * Using and adjusting sensors   * Hydraulic energy * Interpreting measurement results   * Evaluating changes of state * Reading and understanding technical data and measurement curves   * Proportional technology * Getting to know fluid engineering components and their influence and function   * Control technology with position, sequence and pressure control * Demonstrating fluid engineering effects and special features

The most important components at a glance

1 I/O data cable with SysLink connectors (IEEE 488)    7 4/3-way solenoid valve, relieving mid-position (AB −> T)  2 Universal connection unit, digital (SysLink)    8 Pressure sensor 3 Analogue cable, parallel   9 Flow control valve  4 Connection unit, analogue    10 Resistance hose line with quick release couplings  5 EasyPort USB – An interface for measuring, open-loop control, closed-loop control. Connects the simulation to the real world    11 FluidLab®-H Single licence 6 Quick-Fix screw adapter    12 Limit switch, electrical, left-actuated

Equipment set TP 701 – Basic level: Basic proportional hydraulics training

Training aims

Components:   Hydraulic circuits: * Design and function of different proportional valves   * Controlling pressure and speed * Characteristic curves and characteristics of proportional valves   * Reading and creating hydraulic and electric circuit diagrams * Design and function of amplifiers and setpoint specification   * Creating a function diagram * Getting to know the characteristics of the 1 and 2-channel amplifier   * Designing and commissioning control systems, including fault finding * Completely setting the 1-channel amplifier   * Basic circuits for proportional hydraulics, such as pressure stage circuit, rapid traverse feed circuit, pump bypass, approaching positions, controlled acceleration and braking, logically connecting setpoint values, load-independent speeds * Setting the basic current, step current and maximum current   * Getting to know the pressure stage control system * Getting to know the characteristics of the 4/3-way proportional valve and the proportional pressure-relief valve   * Braking a cylinder feed * Deriving the settings for the 2 channel amplifier   * Reversing a hydraulic motor * Setting ramps     Setting process-dependent pressure stages * Deriving the ramp settings from the function diagram     Externally and logically interconnecting setpoint values         Approaching a position with braking Measurements and calculations:     Creating a load-independent feed speed * Determining characteristic curves and characteristics of valves and equipment       * Measuring parameters such as pressure, volumetric flow and time       * Calculating the flow for proportional directional control valves       * Calculating speeds for double-acting cylinders with varying load       * Calculating the natural frequency of a cylinder drive       * Calculating times for acceleration and braking

The most important components at a glance

1 Relay, three-fold   10 Pressure balance (proportional flow control valve)  2 Proportional amplifier   11 Pressure relief valve 3 Setpoint value card    12 Differential cylinder 16/10/200 with cover  4 Signal input, electrical    13 Hydraulic motor  5 Proximity sensor, inductive, M12    14 Flow control valve 6 4/3-way proportional valve   15 One-way flow control valve 7 4/2-way solenoid valve, spring return   16 Pressure gauge  8 Proportional pressure relief valve    17 T-distributor 9 Pressure filter, 5 μm    18 Weight, 9 kg, for cylinder

Equipment set TP 702 – Advanced level: Advanced proportional hydraulics training

Training aims

Components:   Hydraulic circuits: * Determining characteristics curves and characteristics of different sensors   * Controlling pressure, speed, acceleration, delay and position * Coordinating electrical and hydraulic equipment   * Reading and creating proportional hydraulic and electric circuit diagrams * Creating characteristic curves for displacement, pressure and temperature sensors   * Reading motion diagrams Measurements and calculations:   * Designing and commissioning proportional hydraulic control systems, including fault finding * Measuring and processing parameters such as displacement, time, pressure and temperature   * Adjusting and coordinating as per the specified procedure description * Further signal processing of analogue signals   * Using basic circuits for proportional hydraulics such as: speed, rotational speed, stage, acceleration, braking and differential circuits, as well as positioning       * Implementing specific displacement-time and positioning programs       * Setting precise switch-off positions       * Implementing drive acceleration with a proportional pressure-relief valve       * Implementing oscillating movements for a cylinder with a proportional hydraulic control system       * Implementing the specified speed profile by means of an additional bypass circuit and slow retraction to the end positions       * Implementing a travel process with a 2/2-way proportional valve and a proportional pressure-relief valve

The most important components at a glance

1 Setpoint value card    8 Proximity sensor, capacitive, M12  2 Comparator    9 Proximity sensor, optical, M12 3 Time relay, two-fold   10 Non-return valve, delockable  4 Indicator unit and distributor, electrical   11 T-distributor  5 Relay, three-fold    12 Non-return valve 6 Limit switch, electrical, left-actuated   13 Displacement encoder for cylinder 7 Limit switch, electrical, right-actuated    14 Mounting kit for cylinders

Equipment set TP 511 – Basic closed-loop hydraulics training

Training aims

Position control circuits:   Pressure control circuits:   Controllers in hydraulics: * Characteristic curve of a displacement sensor   * Characteristic curve of a pressure sensor   * Controlled systems with and without compensation * Flow rate characteristics of a continuous directional control valve   * Controlled system for pressure control   * Low-delay hydraulic controlled systems * Linear unit as a controlled system for position control   * Characteristics of a PID controller board   * First, second and third order hydraulic controlled systems * Designing and commissioning a position control circuit   * Transition function of a P controller   * Classifying controlled systems according to their step response * Lag errors in the position control circuit   * Control performance of a pressure control circuit with P controller   * Operating point and controller amplification * Position control with a changed controlled system   * Transition functions of I and PI controllers   * Discontinuous controllers * Commissioning a position control circuit with disturbances   * Transition functions of D, PD and PID controllers   * Block diagrams for discontinuous and continuous controllers * Characteristics and transition functions of a status controller   * Empirical parameterisation of a PID controller   * P, I, D, PI, PD and PID controllers * Parameterising a status controller   * Parameterising using the Ziegler-Nichols method   * Status controllers Valves and measuring systems:   * Changed controlled system with disturbances   * Selecting the controller structure * Designation, circuit symbols and function of continuous directional control valves         * Disturbance reaction and control factor * Stationary characteristics and dynamic behaviour of continuous directional control valves         * Designing control circuits * Function, design and mode of operation of a pressure regulating valve         * Hydraulic, mechanical and electrical controllers * Pressure control with a directional control valve         * Analogue and digital controllers * Mode of operation and interface of a measuring system         * Selection criteria for controllers

The most important components at a glance

1 PID controller    8 Flow control valve 2 Status controller    9 Shut-off valve 3 Pressure sensor   10 4-way distributor with pressure gauge  4 Pressure gauge    11 T-distributor  5 Hydraulic motor    12 4/3-way regulating valve  6 Flow sensor    13 Linear drive  7 Pressure filter, 5 μm   14 Weight, 5 kg, for linear drive

Equipment set TP 800 – Mobile hydraulics: From basic principles to mobile machine

Mobile hydraulics from Festo Didactic Mobile hydraulics has a range of specific features compared to conventional industrial hydraulics. These are normally taught directly on a vehicle. But what if the components or the vehicle are not accessible or the entire system is too complex for teaching purposes? Simplified In contrast to a vehicle, with a learning system each hydraulic subsystem can be separately and individually constructed and examined. And measured values can be recorded almost everywhere for improved understanding. Accessible While in a vehicle there is usually little room and access is restricted to qualified personnel, the elements of a learning system are manageable, easy to identify and fault-tolerant. Clean Work on a vehicle usually means dealing with dirt and unpleasant weather. A learning system is clean and ergonomic. Equipment sets: Working hydraulics – Basic level At the basic level, flow control with directional valves with different mid positions are compared in terms of their energy usage. This is done using a cylinder load simulator which, depending on the design, is capable of simulating a wide variety of different load situations. In addition, the topics of holding and lowering the load and two 6/3 way valves for actuation of two drives are discussed using the series, parallel and tandem circuits. As a transition to the Working hydraulics - Advanced level, a simple load sensing controller with constant pump is implemented. Working hydraulics – Advanced level Here, the focus is on load sensing systems with variable displacement pump. This includes the construction, operation and adjustment of a variable displacement pump with a load sensing controller and mobile or control block. The energy usage with flow control, open centre load sensing and closed centre load sensing with a variable displacement pump can then be compared. Remote control and hydraulic pilot control of mobile blocks can also be discussed and developed. In addition, the effects of upstream and downstream pressure balances can be tested. Hydrostatic steering system The working hydraulics can also be extended with a steering system. This teaches the construction and functioning of a hydrostatic steering system, with typical shock and suction valves and double-rod cylinders. The influence and effect of loads on the steering cylinder are investigated. Combinations of working hydraulics and a steering system based on different priorities can also easily be set up. This illustrates the effect of steering activity on the downstream working hydraulics. With the mobile hydraulics equipment set, Festo Didactic closes the gap between the basic principles of hydraulics and hydraulic systems on a vehicle. For an ideal introduction to mobile hydraulics, a hydraulic power unit is available, with variable displacement pump and load sensing controller and a constant displacement pump. This enables both basic and advanced levels to be taught and load simulations to be carried out with just one power unit.

Equipment set TP 801 – Basic level: Mobile hydraulics – Working hydraulics 1

Training aims

Many vehicles and applications make use of constant displacement pumps which continue to provide volumetric flow even when no hydraulic power is required. In TP 801, the energy usage of different systems – also when under load – is compared and assessed. Systems with multiple consuming devices are set up, connected in parallel, tandem and series, and examined in terms of characteristics such as priority, flow rate distribution, and pressure dependency. The training also looks into the basics of holding the load with poppet valves and lowering the load with counter pressure and a counterbalancing valve.

The most important components at a glance

1 Counterbalance valve   10 6/3-way proportional hand lever valve  2 Pressure compensator for open centre load sensing    11 Loading unit/cylinder load simulator 3 3-way pressure reducing valve   12 Diaphragm accumulator with shut-off block  4 Pressure relief valve    13 Hydraulic motor 5 Flow control valve   14 4-way distributor with pressure gauge 6 Non-return valve    15 T-distributor  7 Shuttle valve    16 Pressure switch, electronic  8 Double non-return valve, delockable   17 Flow sensor 9 Shut-off valve

Supplementary equipment set from Hydraulics, Basic level TP 501 to Mobile hydraulics, Working hydraulics 1 TP 801

Training aims

The supplementary equipment set extends TP 501 (order no. 573035) to form TP 801. The necessary accessories from TP 801 are required in order to carry out the exercises. Supplements are available on request for other/older equipment sets. For training content, see Equipment set, Mobile hydraulics, Working hydraulics 1 TP 801.

1 Counterbalance valve   8 6/3-way proportional hand lever valve 2 Pressure compensator for open centre load sensing    9 Diaphragm accumulator with shut-off block  3 3-way pressure reducing valve   10 Loading unit/cylinder load simulator  4 Pressure relief valve    11 Hydraulic motor  5 Flow control valve    12 T-distributor 6 Shuttle valve   13 Pressure switch, electronic 7 Double non-return valve, delockable   14 Flow sensor

Equipment set TP 802 – Advanced level: Mobile hydraulics – Hydrostatic steering system

Training aims

TP 802 promotes the practical testing and technical measurement of the structure and method of operation of a hydrostatic steering system, comprising a steering valve, anti-shock and anti-cavitation valves, steering cylinder(s), constant-displacement pump and (if needed) secondary loads. The basics include the structure of different steering systems with through-rod and differential cylinders, and determining the displacement and the torque dependencies of the steering unit. In addition, emergency steering characteristics are explored and tested. An overload is applied to the system, its behaviour is analysed and anti-shock valves are set accordingly. The steering system’s priority over a secondary load also forms part of this training package.

The most important components at a glance

1 Steering unit  2 Shock and anti-cavitation valve  3 4/3-way hand lever valve, relieving mid-position (AB −> T), detenting 4 Tubing line for unpressurised return  5 4-way return header, unpressurised

Equipment set TP 803 – Advanced level: Mobile hydraulics – Working hydraulics 2

Training aims

* Design, mode of operation and setting of a variable displacement pump with load sensing controller and control block. * Comparing and assessing the energy usage of flow control, open centre load sensing and closed centre load sensing with a variable displacement pump. * Remote control and hydraulic pilot control of control blocks. * Characteristics of load sensing systems with upstream and downstream pressure balances (flow distribution independent of load pressures).

The most important components at a glance

1 Pilot valves (Joystick), 2x2-channel  2 Mobile valve block, Load sensing  3 Pressure compensator, upstream (pre) 4 Pressure compensator, downstream (post)  5 Flow control valve  6 T-distributor  7 Tubing line for unpressurised return

Equipment set TP 810 – Advanced level: Diagnostic system FluidLab®-M: Measurement – Visualisation – Analysis

Training aims

A greater understanding of diagnostic systems System diagnostics, condition monitoring and energy efficiency are becoming more important all the time. A fluid power system can only be optimally set if measurements are taken at the correct points. The correct conclusions must then be drawn from the measurement data. However, with dynamic system conditions, measuring techniques such as the use of a pressure gauge are pushed to their limits. That is why permanent measured data acquisition with visualisation of measurement curves is necessary. Servicing and maintenance personnel then have access to crucial information for the tasks at hand and settings required. FluidLab®-M is the universal measuring tool for all pneumatic and hydraulic training packages.

The most important components at a glance

1 EasyPort USB – An interface for measuring, open-loop control, closed-loop control. Connects the simulation to the real world  2 Analogue cable, parallel 3 I/O data cable with SysLink connectors (IEEE 488)  4 Universal connection unit, digital (SysLink)  5 Quick-Fix screw adapter  6 Connection unit, analogue  7 FluidLab®-M Single license