Hydraulics training packages – Tailored training in industrial and mobile hydraulics
Festo Didactic’s training packages are modular in structure. For example, you could start with the basic level of electrohydraulics and then move onto the advanced level. Or are you more interested in electropneumatics? The choice is yours. You’d like to explore a particular specialised topic? All equipment set components can also be ordered separately, so you can turn your own ideas into reality..
Position it – clamp it – done!With the Quick-Fix mounting system, you can mount all components easily and securely on the profile plate and the profile column of a Learnline workstation. The electrical units are clamped into the ER frame and sequenced individually. The profile slots on the workstations are the same for all pneumatic, hydraulic and electrical units – a single investment, with double the functionality.
Modern measurement and diagnostic technology and cartridge valves are among the international trends in hydraulics. So you’ll find those technologies in our learning systems as well. Benefit from the compact, integrated design, the low weight, ease of handling, and easy-to-read symbol system.
Everything where you want it – systematic storageMost equipment sets are delivered in practical, Systainer-compatible equipment trays. This equipment tray fits in the drawers of the workstations. The large pictogram on the components, designed in accordance with the latest standards, provides clear instructions for connecting the components and ensures short preparation and follow-up times. When dismantling circuits, you can quickly and easily locate where the component goes in the equipment tray.
Connect it – power!No compromise on safety: all electrical components and units are connected with 4 mm safety sockets or safety plugs. The pneumatic power is supplied by the connection of highly flexible plastic tubing to the Quick Star (QS) push-in fitting. The system therefore requires virtually no consumables or tools.
Your choice of training environmentUser-friendly training environments for specific topic areas:
Self-study phases with the training programs
Designing and documentation with FluidSIM®
Practical implementation with the training packages and the exercises in the workbooks
Functional testing and optimisation with measurement technology and FluidLab®
Bigger is not necessarily better. Volumetric flow rates and pressures should be chosen with care and in co-ordination with the system as a whole. This applies especially to hydraulic training systems. High forces and cylinder speeds not only increase the danger for the user, but also require a larger hydraulic power pack with higher power consumption. So our offer is: as large as necessary and as small as possible, without compromising on teaching effectiveness..
The new training packages for mobile hydraulics systematically and informatively explore complex topics and systems, such as work hydraulics, hydrostatic steering and drive systems for the agricultural, forestry and construction vehicle sectors and warehouse and municipal vehicles..
Didactic plusThe workbooks accompanying the training packages contain project-oriented exercises of increasing complexity. There are also positional sketches, illustrations, videos, animations and cross-sectional drawings, which explain how things look in the real world. For a complete and expert treatment of the topic of hydraulics, the training also covers basic physics, technical calculations, safety, efficiency, analytical fault-finding and professional documentation.Practical basic and further training using industrial components provides the confidence to apply the acquired knowledge in the workplace. The components are specially selected for the exercises in the workbook. Note: nearly all hydraulic and electrical connections are located on the easily accessible upper side of the components.
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
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 DidacticMobile 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 systemsSystem 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