This course aims to develop the knowledge and skills in applying the electro-fluid control principles for various applications and approaches based on industrial practices. This course is designed with various hands-on activities and in progressive manner to help the learning in participants to achieve the abilities from interpreting, then applying and finally to designing the control systems with electro-fluid circuits.  The course aims to:

• Be familiarized with electrically-controlled fluid power systems and able to develop the participant’s ability to read, design and construct electro-fluid control systems.
• Demonstrate the electro-fluid system operation and the equivalent ladder logic in circuit diagrams for system operations, control transformers, fuses, circuit breakers, solenoid-operated valves, switches, relays and limit switches.
• To analyse the applications of electro-fluid control systems as motor control, cylinder reciprocation, multiple actuator control, manual, rapid traverse-slow feed, pressure controls and safety shut down systems.
• To apply the knowledge of electro-fluid system for operation with time-relay, pressure switches and photoelectric switches

TARGET GROUP

Middle managers, maintenance supervisors and technicians who are involved in the design, operation and maintenance of pneumatics and hydraulics systems for industrial automation.    

TRAINING METHODOLOGY

For each of the topic covered, the students are first taught the basic concepts. The principle of operation and its practical implementation are then covered. Series of hands-on activities will be conducted to facilitate the learning.  Demonstrations will be conducted and explanations will be given to lead the participants into various applications of the fluid system in the industries. Participants will then perform hands on activities to explore and describe components, functions and circuits as well as the design of the fluid system 

TRAINING PROGRAM OUTLINE

Day 1

Session 1: Introduction to Electrically-Controlled Fluid Power Systems. 

1.1. Basic operation of electrically-controlled fluid power systems

1.2. Applications and advantages of electrically-controlled fluid power systems.

1.3. Components of an electrically-controlled fluid power system: 

1.3.1. Operator station

1.3.2. Control relay station

1.3.3. Conduit

1.3.4. Electric solenoid-operated power valves

1.3.5. Manual input devices

1.3.6. Automatic input devices.

1.4. Sequence of operations of an automatic machine.

1.5. Parts of the control process.

1.6. Servo and non-servo control systems.

Objective:

• Describe the operation of electrically-controlled fluid power systems and their applications as well as advantages.
• Identify the location and describe the functionalities the components applied in constructing an electrically-controlled fluid power system.
• Describe the sequence of operations of an automatic machine and determine the control process.
• Compare the differences and similarities in operation between servo and non-servo control systems.

Session 2: Equipment Familiarization and Safety Considerations.

2.1 Components used in the electro-fluid power training system.

2.2 Power-up the electro-fluid power training system.

2.3 Test the training system.

Objective:

• Identify the components used in the electro-fluid power training system.
• Power-up the electro-fluid power training system.
• Test the trainer to determine the functionalities of the electro-fluid power training system on and perform various activities based on given tasks.

 

Session 3: Electrical Control Concepts.

3.1 Components of an electrical control circuit.

3.2 Closed and open circuits and switches.

3.3 Operation of switches

3.3.1 Normally open contact

3.3.2 Normally closed contact

3.4 Series and parallel logic circuits.

3.5 Using AND, OR, NOT, NAND, NOR logic.

3.6 Power and current in an electrical control circuit

Objective:

• Identify the primary components of an electrical control circuit and the function of each.
• Describe the operation of closed and open circuits and switches.
• Describe the operation of switches using normally open and normally closed contacts.
• Describe the operation of circuits using series and parallel logic circuits.
• Describe the operation of circuits using AND, OR, NOT, NAND, NOR logic.
• Determine the power and current used by an electrical control circuit.

Session 4: Basics of Ladder Diagrams.

4.1 Ladder diagram and pictorial-schematic diagrams

4.2 Read and interpret ladder diagram

4.3 Design with ladder diagram

Objective:

• Describe the advantages of a ladder diagram over pictorial-schematic diagrams.
• Read and interpret a basic ladder diagram.
• Design the flow of electro-fluid system with ladder diagram with standardized label for each component.

Day 2

Session 5: Control Transformers.

5.1 Operation of a control transformer.

5.2 Parts of a control transformer.

5.3 Ladder diagram symbol for a control transformer.

5.4 Step-up and a step-down transformer.

5.5 Isolation transformer.

5.6 Ladder diagram of a circuit using a transformer

Objective:

• Describe the operation of a control transformer and identify the basic parts of a control transformer.
• Draw the ladder diagram symbol for a control transformer.
• Describe the difference between a step-up and a step-down transformer and explain the application of an isolation transformer is used.
• Draw the ladder diagram of a circuit using a transformer to obtain the correct control voltage from a three phase supply.

 

 

 

Session 6 : Circuit protection devices.

6.1 Circuit protection devices in a control circuit

6.2 One-time fuse operates

6.3 Time-delay fuse

6.4 Circuit breakers.

6.5 Symbols for a disconnect switch, fuse, and circuit breaker.

Objective:

• Explain the applications of circuit protection devices in a control circuit.
• Describe how a one-time fuse operates.
• Explain the usage of a time-delay fuse with certain types of loads.
• List the types of circuit breakers.
• Draw the equivalent schematic symbols for a disconnect switch, fuse, and circuit breaker.

Session 7:  Solenoid-operated Fluid Valves.

7.1 Operation of a solenoid

7.2 Current drawn by a solenoid

7.3 Solenoid-operated directional control valves

7.4 Operation of pilot-operated directional control valves

7.5 Solenoid-operated directional control valve circuit

7.6 Manual override of a directional control valve

7.7 Wet-armature type solenoid 

Objective:

• Explain the operation of a solenoid and measure the current drawn by a solenoid
• Describe the operation of 2-position and 3-position solenoid-operated directional control valves as well as the operation of pilot-operated directional control valves.
• Assemble and operate a circuit using a solenoid-operated directional control valve.
• Operate the manual override of a directional control valve.
• List the advantages of a wet-armature type solenoid over an air-gap type.

 

 

Day 3

Session 8:  Pushbuttons.

8.1 Operation and function of pushbutton

8.2 Colour and head type of pushbuttons.

8.3 Ladder diagram symbols for each type of pushbutton.

8.4 Assembly and operation of basic pushbutton circuits

8.5 Pushbuttons in electrical control circuits of ladder logic

Objective:

• Describe the operation and function of the pushbutton as well as the applications of each colour and head type used by pushbuttons.
• Draw the ladder diagram symbols for each type of pushbutton.
• Read and interpret the operation of ladder diagrams representing basic circuit applications of pushbuttons.
• Assemble and operate basic pushbutton circuits by referring to a ladder diagram.
• Develop electrical control circuits in ladder diagram form to perform basic functions involving pushbuttons.

Session 9:  Selector Switches.

9.1 Operation and function of the selector switches

9.2 Types of operators available for selector switches

9.3 Fluid circuitry diagram symbols for 2-position and 3-position selector switches

9.4 Operation of ladder diagram circuits using 2-position and 3-position selector switches

9.5 Assembly and operation of basic selector switch circuits

9.6 Selector switches in fluid circuits

Objective:

• Describe the operation and function of the selector switches
• List the types of operators available for selector switches
• Draw the ladder diagram symbols for 2-position and 3-position selector switches
• Read and interpret the operation of fluid circuit diagram circuits using 2-position and 3-position selector switches
• Assemble and operate basic selector switch circuits by referring to a fluid circuit ladder diagram
• Develop electrical control circuits in ladder diagram form to perform basic functions involving selector switches

Session 10: Indicator Lights.

10.1 Types of indicator lamps

10.2 Function of indicator lens colour 

10.3 Symbols for indicator lights

10.4 Indicator lamps in fluid circuit 

10.5 Operation of a push-to-test indicator lamp

Objective:

• Name the types of indicator lamps
• Describe the function indicated by each type of indicator lens colour
• Draw the fluid circuitry with ladder diagram symbols with indicator lights
• Assemble and operate a basic circuit using indicator lamps by referring to a ladder diagram.
• Describe the operation of a push-to-test indicator lamp
• Develop electrical control circuits to perform basic functions involving indicator lights

 

Day 4

Session 11: Relays.

11.1 Operation of a control relay

11.2 Types of control relays

11.3 Ladder diagram symbol for a control relay

11.4 Operation of a seal-in relay circuit

11.5 Control relays in ladder diagram of electro-fluid systems

Objective:

• Identify the common functions for which a control relay is used and describe the basic operation of a control relay.
• Identify the types of control relays and the applications for each.
• Draw the ladder diagram symbol for a control relay as well as read and interpret the operation of ladder diagram circuits using control relays.
• Explain the operation of a seal-in relay circuit.
• Develop circuits in ladder diagram form to perform basic functions involving control relays.

 

Session 12: Limit Switches.

12.1 Operation of industrial limit switch

12.2 Actuators used with limit switches

12.3 Types of limit switches

12.4 Limit switch symbols in ladder diagram circuits

12.5 Assembly and operation of limit switches in electro-fluid system circuits

Objective:

• List the functions in which a limit switch can be used and describe the operation in an industrial context.
• Identify actuators used with limit switches and their applications
• Identify the types of limit switches used in industry and their appropriate applications
• Read and interpret the operation of ladder diagram circuits using limit switch symbols
• Draw a ladder diagram given a wiring diagram of a circuit using limit switches
• Assemble and operate basic circuits using limit switches by referring to a ladder diagram

Session 13: Motor Control.

13.1 Advantages of using fluid power motors

13.2 Various functionalities of fluid power motors

13.2.1 Single direction motor start/stop

13.2.2 Bi-direction motor start/stop with two pushbuttons

13.2.3 Bi-direction motor start/stop with one pushbutton

13.2.4 Multiple start and stop pushbuttons

13.3 Motor control circuits in ladder diagram

Objective:

• Describe the advantages of using fluid power motors instead of electric motors.
• Read and interpret ladder diagrams of circuits used to perform the functions such as single direction motor start/stop, bi-direction motor start/stop with one and two pushbuttons as well as multiple start and stop pushbuttons.
• Setup and operate motor control circuits by referring to a ladder diagram of the circuit.

Day 5

Session 14: Cylinder Reciprocation.

14.1 Applications of cylinder reciprocation circuits

14.2 Cylinder reciprocation circuits and functionalities in ladder diagrams

14.2.1 Single cycle cylinder reciprocation circuit with one limit switch

14.2.2 Single cycle cylinder reciprocation circuit with two limit switches

14.2.3 Continuous cycle cylinder reciprocation circuit

14.3 Setup and operation of cylinder reciprocation circuits  with a ladder diagram of the circuit

Objective:

• Describe the applications where cylinder reciprocation circuits are used.
• Read and interpret ladder diagrams of circuits used to perform the functions of single cycle cylinder reciprocation circuit with one and two limit switches as well as continuous cycle cylinder reciprocation circuit.
• Setup and operate cylinder reciprocation circuits by referring to a ladder diagram of the circuit.

Session 15:  Multiple Cylinder Control.

15.1 Applications for AND and NAND limit switch logic elements

15.2 Multiple cylinder control and ladder diagrams

15.2.1 Multiple cylinder control with mechanical synchronization

15.2.2 Multiple cylinder control with electrical synchronization

15.3 Setup and operation of multiple cylinder control circuits using both electrical and mechanical synchronization

Objective:

• Describe the applications for AND and NAND limit switch logic elements
• Read and interpret ladder diagrams of circuits used to perform the functions of multiple cylinder control with mechanical and electrical synchronization
• Setup and operate multiple cylinder control circuits using both electrical and mechanical synchronization

Session 16: Manual Controls.

16.1 Purpose of manual controls

16.2 Manual controls in ladder diagrams of electro-fluid circuit

16.2.1 Single-solenoid valve jog control

16.2.2 Double-solenoid valve jog control

16.2.3 Slow-fast jog control

16.3 Assembly and operation of jog controls circuit

Objective:

• Describe the uses of manual controls
• Read and interpret ladder diagrams of circuits that perform the following functions  single-solenoid and double-solenoid valve jog control as well as slow-fast jog control
• Assemble and operate circuits with jog controls

Day 6

Session 17:  Rapid Traverse-Slow Feed.

17.1 Operation of rapid traverse-slow feed control system

17.2 Rapid traverse-slow feed control in ladder diagrams of circuits using 

17.3 Setup and operation of cylinder reciprocation circuit using rapid traverse-slow feed control

Objective:

• Describe the operation and purpose of a rapid traverse-slow feed control system
• Read and interpret ladder diagrams of circuits using rapid traverse-slow feed control
• Setup and operate a cylinder reciprocation circuit using rapid traverse-slow feed control

Session 18: Electrical Pressure Control.

18.1 Operation of a solenoid-operated relief valve

18.2 Applications of solenoid-operated relief valves

18.3 Solenoid-operated relief valves in ladder diagrams of circuits

18.3.1 Pump unloading

18.3.2 Two-speed control

18.3.3 Intermediate pressure control

18.4 Assembly and operation of pilot-operated relief valves

Objective:

• Describe the operation of a solenoid-operated relief valve.
• Name three applications for solenoid-operated relief valves.
• Read and interpret ladder diagrams of circuits using solenoid-operated relief valves to perform the functions of pump unloading, two-speed control and intermediate pressure control.
• Assemble and operate circuits using pilot-operated relief valves.

Session 19: Safety Circuits.

19.1 Operation of the emergency stop and cycle stop functions

19.2 Operation of safety interlocks

19.3 Safety interlocks in ladder diagrams of electro-fluid circuit

19.4 Assembly and operation of safety interlocks circuits

19.5 Assembly and operation of emergency stops and cycle stops circuits

Objective:

• Describe the operation of the emergency stop and cycle stop functions
• Describe the operation of safety interlocks
• Read and interpret ladder diagrams of circuits with safety interlocks as well as the circuits with emergency stop and cycle stop functions
• Assemble and operate circuits using safety interlocks and emergency stops as well as cycle stops

Day 7

Session 20: Time-Delay Relay.

20.1 Operation of fluid time-delay relay

20.2 Operation of solid state time-delay relay

20.3 On-delay, off-delay and time-delay relays

20.4 Functions of a time-delay relay

20.5 Time-delay relays ladder diagrams

Objective:

• Describe the operation of a fluid and solid-state time-delay relay
• Explain the differences between on-delay, off-delay and time-delay relays
• List the functions for which a time-delay relay can be used
• Read and interpret the operation of ladder diagrams representing basic circuit applications of time-delay relays
• Develop electrical control circuits in ladder diagram form to perform basic functions involving time-delay relays  

Session 21: Pressure Switches.

21.1 Operation of a pressure switch

21.2 Types of pressure switches

21.3 Functions of pressure switch

21.4 Types of pressure switch actuators

21.5 Pressure switch in ladder diagram circuit

21.6 Assembly and operation of pressure switches in ladder diagram of the circuit.

 

Objective:

• Describe the operation of a pressure switch and determine various types of pressure switches.
• Identify and describe the functions for which a pressure switch can be used,
• Explain the types of pressure switch actuators,
• Read and interpret the operation of a ladder diagram circuit using a pressure switch.
• Draw a ladder diagram given a wiring diagram of a circuit using a pressure switch.
• Assemble and operate basic circuits involving pressure switches by referring to a ladder diagram of the circuit.

Session 22: Photoelectric Switches.

22.1 Operation of a photoelectric switch

22.2 Types of light sources in photoelectric switches

22.3 Types of detection methods in photoelectric switch

22.4 Diffuse and specular reflection in a photoelectric switch 

22.5 Photoelectric switch in a ladder diagram circuit

22.6 Assembly and operation of photoelectric switches with ladder diagram

Objective:

• Describe the operation of a photoelectric switch.
• Identify the types of light sources used with photoelectric switches and the advantages of each.
• Determine the types of detection methods and the uses of each.
• Explain how to use the characteristics of diffuse and specular reflection in a photoelectric switch application.
• Read and interpret the operation of a ladder diagram circuit that uses a photoelectric switch.
• Draw a ladder diagram given a wiring diagram circuit using a photoelectric switch.
• Assemble and operate basic circuits involving photoelectric switches by referring to a ladder diagram of the circuit.