Operating a Double-Acting Pneumatic Cylinder with START and STOP Push Buttons (Close Priority)

Operating a Double-Acting Pneumatic Cylinder with START and STOP Push Buttons (Close Priority)

Introduction

A double-acting pneumatic cylinder operates using compressed air for both extension and retraction. In this setup, we use START and STOP push buttons to control the movement of the cylinder, with a close priority system. This means that if both buttons are pressed simultaneously, the STOP button takes precedence, ensuring the cylinder retracts for safety and control.

This article covers the working principle, components, pneumatic circuit design, and AutoSIM 200 simulation of this system.

Working Principle

• START Push Button (NO - Normally Open): Activates the cylinder extension when pressed.
• STOP Push Button (NC - Normally Closed): Deactivates extension and forces retraction when pressed.
• Close Priority Logic: The STOP button overrides the START button, ensuring the cylinder retracts when both buttons are pressed at the same time.

Applications

 Safety-critical automation processes
Emergency stop mechanisms
Industrial assembly and material handling
Pressing and clamping operations

Components Required

1. Double-Acting Cylinder – Performs bidirectional movement.
2. 5/2-Way Double Pilot Valve – Controls air supply for extension and retraction.
3. START Push Button (3/2-Way NO Valve) – Sends air to the extension side.
4. STOP Push Button (3/2-Way NC Valve) – Sends air to the retraction side.
5. Air Compressor – Provides compressed air.
6. Flow Control Valves (Optional) – Controls the speed of movement.
7. Air Tubing and Fittings – Connects the components.

Pneumatic Circuit Design

Step 1: Understanding the Valve Function

• START PB (NO - Normally Open, 3/2-Way Valve)

  • When pressed → Air flows to pilot side A of the 5/2-way valve, extending the cylinder.
  • When released → The cylinder remains extended due to the pilot signal holding the valve in position.

• STOP PB (NC - Normally Closed, 3/2-Way Valve)

  • When pressed → Sends air to pilot side B of the 5/2-way valve, retracting the cylinder.
  • When released → The cylinder remains retracted, overriding the START command.

Step 2: Circuit Working Mechanism

1. Press START Button:

   • The 3/2-way NO valve opens.
   • Air enters the pilot port A of the 5/2-way valve.
   • The cylinder extends.

2. Press STOP Button:

   • The 3/2-way NC valve opens.
   • Air enters the pilot port B of the 5/2-way valve.
   • The cylinder retracts.
   • Since STOP has priority, the cylinder remains retracted even if START is pressed.

Implementation in AutoSIM 200

To simulate this circuit in AutoSIM 200, follow these steps:

1. Open AutoSIM 200 and create a new project.
2. Add components from the pneumatic library:
   • Double-acting cylinder
   • 5/2-way double pilot valve
   • 3/2-way NO valve (START PB)
   • 3/2-way NC valve (STOP PB)
   • Air supply
3. Connect the components using air tubing.
4. Run the simulation and observe the following:
   • Press START PB → Cylinder extends.
   • Press STOP PB → Cylinder retracts.
   • If both buttons are pressed, the STOP PB takes priority.

Conclusion

Using a double-acting pneumatic cylinder with START and STOP push buttons ensures controlled movement, with the STOP button having priority for safety. This setup is commonly used in industrial automation, machine safety systems, and material handling applications.

Click here to watch video https://youtu.be/K8iEcbeOj4Y

Operating a Double-Acting Pneumatic Cylinder with a Manual Hand Lever

Introduction

A double-acting pneumatic cylinder is a commonly used actuator in industrial automation, capable of extending and retracting using compressed air. Unlike single-acting cylinders, which rely on a spring for retraction, double-acting cylinders use air pressure for both movements.

In this article, we will discuss the working principle, components, and pneumatic circuit design for operating a double-acting cylinder using a manual hand lever valve.

Working Principle of a Double-Acting Cylinder

• Two air ports: One for extension and one for retraction.
• Air pressure controls both movements, making it stronger and more reliable than a single-acting cylinder.
• It is ideal for continuous or repetitive motion applications in automation.

Applications of Double-Acting Cylinders

Lifting and lowering in material handling
Clamping and holding in machining processes
Punching and pressing in manufacturing
Robotic arm movements

Components Required

To operate a double-acting cylinder using a manual hand lever, the following components are required:

1. Double-Acting Cylinder – The actuator that moves in two directions.
2. 5/2-Way Hand Lever Valve – A manually operated directional control valve.
3. Air Compressor – Provides compressed air for operation.
4. Flow Control Valves (Optional) – Regulates the speed of movement.
5. Air Tubing and Fittings – Connects all components in the pneumatic circuit.

Pneumatic Circuit Design

Step 1: Understanding the 5/2-Way Hand Lever Valve

A 5/2-way valve has:

• 5 ports:
  • P – Air supply
  • A – Cylinder extension port
  • B – Cylinder retraction port
  • R1, R2 – Exhaust ports
• 2 positions:
  • Position 1 (Lever Left) – Air flows to port A, extending the cylinder.
  • Position 2 (Lever Right) – Air flows to port B, retracting the cylinder.

Step 2: Circuit Diagram and Working

1. When the hand lever is pushed forward:

   • The valve shifts, allowing compressed air into port A.
   • The piston extends.
   • Air from port B exits through the exhaust.

2. When the hand lever is pulled backward:

   • The valve shifts to the opposite position.
   • Air enters port B, causing the piston to retract.
   • Air from port A exits through the exhaust.

Implementation in AutoSIM 200

To simulate this circuit in AutoSIM 200, follow these steps:

1. Open AutoSIM 200 and create a new project.
2. Add components from the pneumatic library:
   • Double-acting cylinder
   • 5/2-way manual hand lever valve
   • Air supply
3. Connect the components using air tubing.
4. Run the simulation and operate the hand lever to observe the cylinder’s extension and retraction.

Conclusion

A double-acting cylinder with a manual hand lever valve provides precise control for industrial applications. The 5/2-way valve allows easy switching between extension and retraction, making it ideal for mechanical control in automation systems.

Click here to watch video https://youtu.be/vMmYtsSlBro

S7-1500 Hardware Configuration Using TIA Portal V19

 Introduction

The Siemens S7-1500 series PLCs are powerful automation controllers designed for high-performance industrial applications. Configuring an S7-1500 PLC in TIA Portal V19 is an essential step in developing a structured and efficient automation system.

This article provides a step-by-step guide to configuring S7-1500 hardware, including adding a PLC, configuring I/O modules, setting up communication, and downloading the configuration to the hardware.

Step 1: Open TIA Portal V19 and Create a New Project

1. Launch TIA Portal V19.
2. Click on "Create New Project" and enter:
   • Project Name (e.g., "S7-1500_Config")
   • Path to Save the Project
   • Project Description (Optional)
3. Click "Create" to open the main project workspace.

Step 2: Adding the S7-1500 PLC to the Project

1. In Project View, navigate to "Devices & Networks".
2. Click "Add New Device".
3. Under "Controller", select "SIMATIC S7-1500".
4. Choose the specific CPU model (e.g., CPU 1511-1 PN).
5. Click "Add" to insert the selected PLC into the project.

Step 3: Configuring the PLC Hardware

1. Set Up the Rack and CPU Configuration

• The rack layout appears in the device configuration window.
• Ensure the CPU is placed in Slot 1 (default for S7-1500).

2. Adding I/O Modules

1. Click on the rack’s empty slots to add I/O modules.
2. Select the appropriate digital/analog input/output modules from the hardware catalog (e.g., SM 521 DI 16x24VDC for digital inputs).
3. Drag and drop modules into the rack slots as per the system requirements.

3. Configuring I/O Addresses

1. Select an I/O module and go to the "Properties" tab.
2. Assign input and output addresses (e.g., Q0.0, I0.0).
3. Ensure that the addresses do not overlap with other modules.

Step 4: Network Configuration and IP Address Assignment

1. Open the PLC Properties

1. Select the CPU module and go to "Properties" → "PROFINET Interface".
2. Click on "Ethernet Addresses".

2. Set the IP Address

• Assign a unique IP address to the PLC (e.g., 192.168.0.1).
• Set the Subnet Mask (e.g., 255.255.255.0).

3. Configure PROFINET or Other Communication Protocols

• If using PROFINET, ensure all connected devices (HMIs, Drives, Remote I/Os) are in the same IP range.
• If required, set up PROFIBUS or Modbus TCP communication.

Step 5: Compile and Download the Configuration

1. Click "Compile" to check for errors.
2. If no errors, click "Download to Device".
3. Choose the communication interface (e.g., PN/IE for PROFINET).
4. Click "Start Search" to find connected hardware.
5. Select the PLC and download the configuration.
6. Set the PLC to RUN mode for execution.

Step 6: Testing and Monitoring the Configuration

1. Open "Online & Diagnostics" in TIA Portal.
2. Check the status of the PLC and I/O modules.
3. Use "Force Table" to manually test inputs and outputs.
4. Monitor real-time data and diagnostics to ensure proper operation.

Conclusion

Configuring an S7-1500 PLC in TIA Portal V19 is a crucial step in industrial automation. By following this guide, you can:

Set up an S7-1500 CPU and I/O modules
Assign correct I/O addresses
Configure PROFINET communication
Download and test the configuration

This structured approach ensures efficient PLC operation and seamless communication with field devices.

Click here for video 

https://youtu.be/_ddZ2bbEYUQ