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2. Globally active solution provider
for
Industrial Automation, Seminar
and Training in pneumatics .

3. Festo -A Historical Perspective
1925
Festo founded in Esslingen,
Germany by Mr. Gottlieb
Stoll to manufacture Wood-
working machines
1952
Festool (independent from
April 2000) -Powertools
1957
Festo Pneumatic Automation
components and system
solutions (pneumatic and
electronics)
1965
Festo Didactic Learning
systems for automation
Festo Headquarters in Esslingen Berkheim
Introduction to Festo

4. Festo -An Independent Family Enterprise
Festo Automation Group,
internationally
represented in over 176
countries.
56 independent Festo
companies with over
250 branch offices
Turnover of 1.5 Billion
Euro, 55% Export.
Over 11.500 employees.
R & D 7% of turnover
p.a.
Over 300,000 customers
in 176 countries.
Vocational and further
training, 1.5% of
personnel budget.
Cylinder production and Customer Service Centre
in St. Ingbert
A Globally Active Organisation
Festo Production Facilities.
GPC INDIA

5. Introduction to Festo
Didactic
Didactic -A Greek
word. Means learning.
Promotes the use of
automation in industry
by educating users on
the applications and
use of standard
available products.
Festo Didactic has its
own product range.
Festo Didactic present
in over 75 countries
worldwide. Annual
turnover 30 Mio.Euro.
100 employees.
In India Festo Didactic
-The training division
of Festo Controls Pvt.
Ltd.
Festo Didactic Headquarters in Esslingen-Denkendorf,
near Stuttgart
Festo Didactic FMS.

6. Festo Didactic Products & Services
Festo Didactic products and services fall into the
following categories:
Training
Seminars.
Training Kits.
Training Aids.
Courseware.
Software.
Consultancy.

7. Training Seminars are offered on
:
Pneumatics.
Electro-
Pneumatics.
Advanced
Pneumatics.
Customized need
based Training.
Hydraulics.
Festo Sponsored Mechatronics Olympiad
Qualifications in Automation

8. Festo Didactic Products & Services
In India, Training
seminars are being
conducted at :
Bangalore (HO).
Mumbai.
Delhi.
Coimbatore.
Ahmedabad.
Pune.
Chennai

9. Festo Didactic Products & Services
Training Kits are available for
Pneumatics.
Electro-Pneumatics.
Hydraulics.
Electro-Hydraulics.
Programmable Logic
Controllers.
Industrial Process
Control.
Mechatronics &
Robotics.
Customized kits.

10. Types of training aids and
accessories available from Festo :
Overhead Projector
Slides.
Magnetic Circuit Symbols.
Cut-Sections.
Transparent Working
Models.
Videos.
Educational Software.
Low Noise Compressors.

11. Courseware
Text books.
Work books.
Reference books.
Recommended by
major universities in
India including
Bombay University.
Detailed list available
on request.

12. Pneumatic Grippers.
Cutting Costs with
Pneumatics.
Servo Pneumatic Positioning.
Closed Loop Pneumatics.
Robotics.
Fieldbus Technology.
Automated Production.
The Amazing World of
Pneumatics.
Handling Technology.
Major Courseware Topics
Basic Pneumatics.
Electro Pneumatics.
Hydraulics.
Electro Hydraulics.
Proportional Hydraulics.
Programmable Logic
Controllers.
Sensors.
Mechatronics.
Fundamentals of Pneumatic
Control technology.

13. SOFTWARE FOR EDUCATION
The Fascination of Technology.
An interactive journey through time and the
fascinating world of technology. From the
wedge to the conveyor belt and to how
technology will affect our future. Includes
animations, videos and commentaries.
Fluid Studio -Pneumatics / Hydraulics.
An interactive self study program to teach the
fundamentals of Pneumatics or Hydraulics.
Includes various forms of exercises and
multiple choice questions.
Cosimir Educational.
Interactive learning program for robot
technology and professional 3D software
program or programming and simulation of
robots using numerous pre-designed robot
cells.

14. Software for Design & Simulation :
FluidSIM 3.6 for Pneumatics & Hydraulics.
Useful for drawing and archiving circuit diagrams for
later use.
Accurately simulates circuits, with full animation.
Includes several educational videos and animations
of components to make understanding easy.
COSIMIR Professional.
Used for simulation & control of multi-robotic
systems in 3D space, with anti collision detection and
Virtual Reality features.
InTouch.
Process visualization software for visualizing,
controlling and monitoring industrial processes.

15. Festo Didactic Consultancy Services
Design & layout of complete training facility from concept to
implementation.
Training kit design.
Designing course content & handouts.

16. Automation in Industry
Choice of Working Media:
Pneumatics.
Hydraulics.
Electricity & Electronics.
Combinations of the above.
Combinations of technologies offer synergy.
Has the capability of expanding the scope of
applications tremendously.
Pneumatics Versus Hydraulics
Typical Hydraulic Applications

17. “Pneumatics is the name given to the branch of
physics which deals with the properties,
motions and behavior of air”
Introduction to Pneumatics
PNEUMA : means “breath” in Greek

18. Energy medium selection criteria
•Force exerted
•Distance through which the force can be
applied

19. Automation in Industry
Media Selection Criteria:
Speed of Operation.
Reliability.
Service Life.
Sensitivity to Environment.
Ease of Maintenance.
Available Expertise.
Training Requirements.
Availability
Transportability
Storability
Explosion proof nature
Cleanliness
Overload safety

20. Advantages of
Compressed Air

21. Transport
•Aircanbeeasilytransportedin
pipelines,evenoverlargedistances

22. Storage
Acompressorneednotbein
continuousoperation.
Compressedaircanbestoredinareservoir
andremovedasrequired.
Thereservoircanbetransportable.

23. Temperature
Compressedairisrelatively
insensitivetotemperature
fluctuations.
Thisensuresreliableoperation,
evenunderextremeconditions.

24. Explosion Proof
Thereisminimalriskof
explosionorfire.
Noexpensiveprotectionagainst
explosionisrequired.

25. Cleanliness
Unlubricatedexhaustairisclean.
Anyunlubricatedairdoesnot
causecontamination.
Usefulinfood,woodandtextile
industries.

26. Components
Operatingcomponentsareofsimple
constructionandthereforerelatively
inexpensive.

27. Speed
Compressedairisaveryfast
workingmedium.
Highworkingspeedscanbe
obtained.

28. Adjustable
Withcompressedaircomponents
speedsandforcesareinfinitely
variable.

29. Overload safe
Pneumatic tools and operating
components can be loaded to the
point of stopping and therefore
overload safe.

30. Disadvantages of
compressed air

31. Preparation
Compressedairrequiresgood
preparation.
Dirtandcondensateshouldnot
bepresent.

32. Compressible
Itisnotalwayspossibletoachieve
uniformandconstantpistonspeeds
withcompressedair.

33. Force requirement
Compressedairiseconomicalonlyup
toacertainforcerequirement.
At6-7bar,anddependentonthe
travelandspeed,theoutput
limitisbetween20000and
30000Newtons.

34. Noise level
The exhaust air is loud.
The problem is largely solved
with silencers.

35. Costs
Compressed air is a relatively
expensive means of conveying
power.
The high energy costs are
partially compensated by
inexpensive components and
higher performance.

36. Compressed Air as a
Working Medium
Advantages:
•Air is available everywhere
•Compressed air is easily conveyed in pipelines over large
distances
•Compressed air need not be returned
•Compressed air is insensitive to temperature fluctuations
•Compressed air is explosion proof
•Compressed air is clean
•Compressed air is fast

37. Compressed Air as a
Working Medium
Disadvantages:
•Straight line movement can be produced directly.
•Compressed air is a relatively expensive means of
conveying energy
•Compressed air requires good conditioning
•It is only economical up to a certain force
expenditure.
•Air is compressible. Exhaust air is loud (reduced by
using silencers).
•The oil mist mixed with air for lubricating purposes
exhaust or escapes to the atmosphere

38. Structure of pneumatic control

39. Elements in a Pneumatic System
Hierarchy of Elements
Flow Control Valve
Quick Exhaust Valve
Direction Control Valve
[Power Valve]
Service Unit
Pressure Regulator
Main Air Supply
Flow Control Valve
Quick Exhaust Valve
High Pressure,
High Flow
Rate Zone
>4 Bar
Low Pressure,
Low Flow
Rate Zone
<4 Bar
Pneumatic
Actuation
Pneumatic
Actuation
Low Pressure,
Low Flow
Rate Zone
<4 Bar
Direction Control Valves
Pressure Sequence Valves
Pneumatic Timers
Dual Pressure [AND] Valves
Shuttle [OR] Valves
Limit Switches
Push Buttons
Direction Control Valves
Pressure Sequence Valves
Pneumatic Timers
Dual Pressure [AND] Valves
Shuttle [OR] Valves
Limit Switches
Push Buttons

40. Drawing Functional Block Diagrams
FC
5/2 Way
QE
LS1 Timer
LS1 LS2
PB LS2
Block diagrams are more
easily understood by a
layman. No knowledge of
symbols is necessary.
They are faster and easier
to draw.
Corrections are also easier
to make.
A block diagram can be
easily converted into a
circuit diagram.
Individual blocks in a
diagram may represent a
single item, or multiple
items, performing a certain
function.

41. Correct Method of Drawing Circuits

42. Actuators
An actuator is an output device for the
conversion of supply energy into useful
work. They can be described Into two
groups.
Linear Motion
•Single Acting Cylinders
•Double Acting Cylinders
Rotary Motion
•Air Motor
•Rotary Actuator

43. Actuators Operation
An Actuator Can be Controlled by the
Following Methods:
•Pneumatic
•Hydraulic
•Electrical

44. Linear motion
•Single Acting Cylinders
•Double Acting Cylinders

45. Rotary motion
•Rotary actuators-single and double
acting
•Pneumatic motor-continuous motion

46. Single acting cylinders
.

47. Single acting cylinders
.

48. Single acting cylinders
.

49. Single acting cylinders
.

50. Single acting cylindersSingle acting cylinders Reed Switches

51. Single acting cylinders

52. Single acting cylinders

53. Single acting cylinders

54. Single acting cylinders

55. Single acting cylinders

56. Single acting cylinders

57. Single acting cylinders

58. Single acting cylinders

59. Force = Pressure x Area (piston)
Single acting cylinders

60. Force = Pressure x Area (piston)
Single acting cylinders

61. Force = Pressure x Area (piston)
Single acting cylinders

62. Force = Pressure x Area (piston)
Single acting cylinders

63. Force = Pressure x Area (piston)
Single acting cylinders

64. Force = Pressure x Area (piston)
Single acting cylinders

65. Double rod double acting
cylinders

66. Multi-position cylinders

67. Multi-position cylinders

68. Multiposition cylinders
.
1 32

69. Multiposition cylinders
.
1 32

70. Multiposition cylinders
.
1 32

71. The Rodless Cylinder
•Conventional Double Acting Cylinders require
space to house the cylinder.
•Plus space to carry out the work.
•More effective use of the available space can be
made by using Rodless Cylinders.

72. Rodless Cylinder -
Mechanically Coupled
Body of Cylinder
End caps with
cushioning and
adjustment
Internal seal
Protection strip
Piston and carriage
assembly
Clamp for seal and
protection strip

73. Rodless Cylinder -
Mechanically Coupled
.

74. Rodless Cylinder -
Mechanically Coupled
.

75. Rodless cylinder -
mechanically
coupled

76. Rodless Cylinder -
Mechanically Coupled

77. Rodless Cylinder -
Mechanically Coupled

78. Rodless Cylinder -
Mechanically Coupled

79. Rodless Cylinder -
Mechanically Coupled
.
Cylinder Barrel
End Caps
with cushioning
adjustment
Piston assembly
MagnetsBearings Seals
Cushioning
Pistons
Magnets, Bearings, Seals, Cushioning Pistons
Yoke assembly
MagnetsBearingsWipers
Magnets, Bearings, Wipers

80. Rodless Cylinder -
Mechanically Coupled
.

81. Rodless Cylinder -
Mechanically Coupled
.

82. Rodless Cylinder -
Mechanically Coupled

83. Rodless Cylinder -
Mechanically Coupled

84. Driven
Shaft with
gear
End Cap with
Shock
absorber type
cushioning
Adjustable
Body of Actuator
Pistons with ‘Rack’
arrangement
End cap with
pneumatic
connections
Rack and pinion rotary
actuator

85. Rack and pinion rotary
actuator

86. Rack and pinion rotary
actuator

87. Rack and pinion rotary
actuator

88. Rack and pinion rotary
actuator

89. Rack and pinion rotary
actuator

90. Rack and pinion rotary
actuator

91. Rack and pinion rotary
actuator

92. Rack and pinion rotary
actuator

93. Rack and pinion rotary
actuator

94. Rack and pinion rotary
actuator

95. Rack and pinion rotary
actuator

96. Vane Type Rotary Actuator

97. Vane Type Rotary Actuator

98. Vane Type Rotary Actuator
.

99. Vane Type Rotary Actuator
.

100. Vane Type Rotary Actuator
.

101. Vane Type Rotary Actuator
.

102. Linear and Rotary
Actuator Combination

103. Linear and Rotary
Actuator Combination

104. Air Motor

105. Air Motor

106. Air Motor

107. High Precision Guidance
Unit

108. High Precision Guidance
Unit

109. Cylinder seals

110. Cylinder seals

111. Cylinder mountings
.
Front swivel flange Rear flange
Front flange
Centre sswivel flangeRear sswivel flange Foot mounting
Rear mounting Swivel flange

112. PNEUMATIC SYMBOLS

113. The development of pneumatic systems
is assisted by a uniform approach to the
representation of the elements and the
circuits. The symbols used for the
individual elements must display the
following characteristics:
Numberofswitchingpositions
Numberofconnections
Actuationandreturnactuationmethods
Function
Simplifiedrepresentationoftheflowpath
Pneumatic Symbol

114. Asymboldoesnotrepresentthe
followingcharacteristics:
•Sizeordimensionsofthecomponent
•Particularmanufacturer,methodsof
constructionorcosts
•Operationoftheports
•Anyphysicaldetailsoftheelements
•Anyunionsorconnectionsotherthan
junctions
ThestandardusedisISO1219
Pneumatic Symbol

115. Symbol development

116. Ports and Positions

117. Energy supply
•Compressor with fixed capacity
•Air receiver and ‘T’ junction

118. •Air filter
•Air lubricator
•Pressure regulator
Air Service Equipment

119. Air service unit
•filter
•Regulator
•Gauge
•Lubricator
Simplified air Service unit
Air Service Equipment

120. Directional Control Valves

121. •Methods of actuation
•Mechanical
• General manual operation
• Push button
• Lever operated
• Detent lever operated
Directional Control Valves

122. •Methods of actuation
•Mechanical
• Foot pedal
• Roller operated
• Idle return, roller
Directional Control Valves

123. •Methods of actuation
•Mechanical
•Spring return
•Spring centered
Directional Control Valves

124. •Methods of actuation
•Pneumatic
•Direct pneumatic actuation
•Indirect pneumatic
•actuation (piloted)
Directional Control Valves

125. •Check valve
•Spring loaded check valve
•Shuttle valve: ‘or’ function
Non -Return Valves

126. Non-return valves
•Two pressure valve:
‘AND’ function
•Quick exhaust valve

127. Flow control valves
•Flow control valve adjustable
•One-way flow control valve

128. Pressure valves
•Adjustable pressure regulating valve,
• non-relieving type
•Adjustable pressure regulating valve,
relieving type (overloads are vented)

129. Pressure valves
•Sequence valve combination

130. Single acting cylinder
Double acting cylinder
Double acting cylinder with
double ended piston rod
Rodless cylinder
Linear Actuators

131. Linear actuators
•Double-acting cylinder with non-
adjustable cushioning in one direction
•Double-acting cylinder with single
adjustable cushioning
•Double-acting cylinder with adjustable
cushioning at both ends

132. Rotary actuators
•Air motor, rotation in one direction,
fixed capacity
•Air motor, rotation in one direction,
variable capacity
•Air motor, rotation in both directions,
variable capacity
•Rotary actuator, limited travel, rotation
in both directions

133. Exhaust port
•Exhaust port with threaded
connection
•Silencer
•Line connection
Auxiliary Symbols

134. Auxiliary symbols
•Crossing lines (not connected)
•Pressure gauge
•Visual indicator

135. Port labelling
.
13
2
5
1
3
24
Supply
Outlet
Exhaust
Pilot
P
P
P
A
A B
A, B, C
R
R S
R, S, T
Z
Z
Y
Y
X, Y, Z
1
2, 4,
3, 5,
12
14
Letters Numbers
14

136. Exhaust from pilot stage
84 82
Port Labelling

137. Pilot operated non-return valve
1
2
21

139. Switches and contacts

140. Switches and contacts

141. Normally open switch

142. Normally closed switch

143. Changeover switch

144. Switches

145. Momentary and sustained
switches

146. Sustained normally open
switch

147. Changeover switch

148. Normally open contact

149. Normally closed contact

150. Changeover contact

151. Typical push button
switches

152. Relays

153. Relays
ARelay has Certain Characteristics
•Low Maintenance
•Able to Switch a Number of Independent
Circuit Paths
•Easily Adaptable to Various Operating
Voltages
•High Operating Speed, ie. Short Switching
Times
•Can be Used as a Logic or Interlocking
Device

154. Relay Contact Configuration

155. Relays, timers and solenoids

156. Relays and solenoid coils

157. Electrical Output Devices

158. Basic logic functions
There are four commonly used logic
functions in Electro-Pneumatics.
•YESFunction
•NOTFunction
•OR Function
•ANDFunction

159. Basic electrical circuits
YES Function+24V
0V
+24V
0V
Push Button
Lamp

160. Basic electrical circuits
NOT Function+24V
0V
+24V
0V
Push Button
Lamp

161. Basic electrical circuits
OR Function+24V
0V
+24V
0V
S1
Lamp
S2

162. Basic electrical circuits
AND Function+24V
0V
+24V
0V
S1
Lamp
S2

163. Classification of Sensors
Sensors are classified as either:
Contact type
Non-contact type (proximity sensors)
Proximity sensors being the more
commonly used sensor.

164. Limit Switches
Limitswitchesareconsideredtobecontact
sensors,asitneedstobeactuatedtogivea
signaloutput

165. Reed Switches1
1
a)
b)
Most Widely Known
and Used as
Cylinder Switches
Magnet
Magnet

166. Glass Tube filled with
nitrogen
Reed contactsLED
indicator

167. 24v

168. Reed Switches

169. Sensor Switching Distance
Sensor
Object
S
n
S
n= Switching Distance

170. Sensor Hysteresis
Sensor Object
S
n
h = Hysteresis
h
S
n= Switching Distance

171. Classification of Sensors
Sensors are further categorized as either :
Binary
Analogue.
Binary sensors convert a physical quantity
into a binary signal which means it has
two switching states. The most common
being an electrical signal ONor OFF.

172. Types of Sensors

173. Sensors

174. Inductive SensorsActive surface
LED
Cable or
plug-in connection

175. Inductive Proximity Sensors
Connection cable
LED indicator
Resonant circuit coil
High Frequency magnetic field
(300 to 800 kHz) Active Surface

176. Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
ON
OFF
Inductive Proximity Sensors

177. Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
ON
OFF

178. Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
ON
OFF

179. Inductive Proximity Sensors
•The bigger the coil, the greater the
active switching gap.
•Inductive sensors can only detect
metals.
•Different switching distances for
different metals

180. Selection Criteria
•They can be selected according to the
material which they are to detect.
•Metals of any kind can be detected
easily and economically with inductive
sensors if short switching distances
only are required (eg. 0.4 …. 10 mm)

181. Uses of Inductive Proximity Sensors
Inductive sensors detect metals and operate
quickly, reliably and tirelessly. They are used
to:
•Count
•Identify
•Detect
•Switch
•Control
•Check
•Distinguish
•Sort
•Position

182. Inductive Sensors

183. Capacitive Sensors

184. Capacitive Proximity
Sensors
Connection cable
Adjusting screw
LED indicator
Active surface
Active electrode
Earth electrode
Electrostatic field
Sensor is looking for a
change in capacitance in the
active field

185. Capacitive Proximity
Sensors
•Almost similar to the inductive sensor.
•Able to detect most materials.
•Switching distance adjustable.

186. Selection Criteria
Capacitive proximity sensors are
suitable for the detection of a wide
range of materials, but again only
for relatively small distances,
similar to inductive proximity
sensors.

187. Target

191. Capacitive Proximity
Sensors
Detection of matt, black objects.

192. Optical Proximity Sensors
There are three different
types of optical
proximity sensors:
•Through beam optical
sensor
•Retro-reflective optical
sensor
•Diffuse optical sensor

193. Solenoid valves
The directional control valves used in
electro pneumatics are similar to those
used in pure pneumatics. The only
difference is that they are actuated by
solenoids.

194. Solenoids

195. 2/2-way single solenoid
valve

196. 3/2-way single solenoid
valve

197. Pilot signal flow
ELECTRICAL SIGNAL
APPLIED TO
SOLENOID
SOLENOID ACTUATES
PILOT VALVE
PILOT ACTUATES
MAIN VALVE

198. Pilot control

199. 3/2-way single solenoid valve with
pilot control

200. 3/2-way single solenoid valve with pilot
control2
1 3

201. 3/2-way single solenoid valve with pilot
control2
1 3
Y1

202. 5/2-way single solenoid valve with pilot control

203. 5/2-way single solenoid valve with pilot control
2
(B)
3
(R)
1
(P)
5
(A)
4
(S)

204. 5/2-way single solenoid valve with pilot control
2
(B)
3
(R)
1
(P)
5
(A)
4
(S)

205. 5/2-way single solenoid valve with pilot control
2
(B)
3
(R)
1
(P)
5
(A)
4
(S)

206. 5/2-way single solenoid valve with pilot control
2
(B)
3
(R)
1
(P)
5
(A)
4
(S)

207. 5/2-way single solenoid valve with pilot control
2
(B)
3
(R)
1
(P)
5
(A)
4
(S)

208. 5/2-way single solenoid valve with pilot control
2
(B)
3
(R)
1
(P)
5
(A)
4
(S)

209. 5/2-way single solenoid valve with pilot control
2
(B)
3
(R)
1
(P)
5
(A)
4
(S)

210. 5/2-way single solenoid valve with pilot control
2
(B)
3
(R)
1
(P)
5
(A)
4
(S)

211. 5/2-way single solenoid valve with pilot control
2
(B)
3
(R)
1
(P)
5
(A)
4
(S)

212. 5/2-way double solenoid valve with pilot
control

213. 5/3-way double solenoid valve
with pilot control

214. 5/3-way double solenoid valve
with pilot control

215. 5/3-way double solenoid valve
with pilot control

216. 5/3-way double solenoid valve
with pilot control
5 3
4 2
5
4
1
3
2
5
4
1
3
2

217. Pneumatic-Electic Converter
(PE Switch)

218. Pressure Switches
Two-Wire
Technology

219. Component Handling
Mounting Arrangements
for Limit Switches

220. Component Handling
Components requiring two
slots for mounting can fall
if not mounted correctly.
e.g. Pneumatic Counter
& Electrical Pressure
Switch
Press blue lever to mount
Or remove components

221. Component Handling
Press blue ring and
gentlypull the
tube
to disconnect
Blocking of two
connectors
Blocking a single
connector

222. Component Handling
Lift knob to set
pressure.
Set pressure to 3 Bar.
If there is no pressure,
first check if the
compressor is ON.
Output valve

223. Component Handling
Electrical Pressure Switches and
Pressure Sequence Valves
are not to be adjusted.
They are preset to work at about 4 bar.

224. Component Handling
No components should
be fixed in front of a
cylinder.
All components are
marked with their
respective symbols.

225. Electro-Pneumatic Components
Push Button Box Relay Box

226. Electro-Pneumatic Components
Timer Box Distributor Box

227. Electro-Pneumatic Components
Looped
connections
Power Supply
input connections
Positive and Negative
supply lines
internally connected

228. Electro-Pneumatic Components
Pressure Switch
port markings. Use
only the port marked P1.
Do not make any
connections to port P2.