1

Sample Tasks Automation Competition Task Descriptions

TASK A: Pneumatic sequence Weighting (points out of total): 30 / 100 Maximum time allowed, t max: 60 minutes Problem: Use Festo TP101 equipment set to design, assemble and commission a pneumatic circuit with the sequence of

úû

ùêë

é÷÷ø

öççè

æ--

÷÷ø

öççè

æ ++

BA

barA

sB ,0.4

,2,

Circuit requirements:

1. Adjust the supply pressure to 5.0 bars.

2. Cylinders A and B are to be double acting cylinders with cushioned end stops.

3. The cycle is to be initiated by simultaneously pressing two normally closed 3/2 way valves configured using a dual pressure valve (AND).

4. Once the cycle is started it will complete one cycle and then come to rest.

5. Use appropriate sensors to ensure that cylinders A and B are in their retracted positions before the cycle can start. Note that there are two cylinder-attached proximity sensors and two roller lever valves available. The choice of sensor types and location is to be determined by the teams.

6. Add speed control element to cylinder B to limit its forward speed while maintaining maximum force. Full forward stroke is to be achieved in 3.0 ±0.5 s.

7. The last step of the cycle includes both cylinders returning at the same time, however, Cylinder B is to retract fast through a quick exhaust valve.

8. Use a flow restrictor to starve cylinder A when it is moving forward. Add a gauge to observe the pressure slowly increasing in cylinder A to 4.0 bar.

9. The Cylinder A should have a pilot actuated and spring return 5/2 way valve and Cylinder B is to have a pilot actuated and pilot return 5/2 way valve.

2

Sample Tasks Automation Competition Task Descriptions

TASK B: Electro-pneumatic (Hard-wired system) Weighting (points out of total): 30/ 100 Maximum time allowed, t max: 60 minutes Problem: Design, Assemble, and Commission the following sequence using hardwired electro-pneumatic elements.

[ ]--++ ABAB ,,, Circuit requirements:

1. Supply pressure is to be limited to 5.5 bars.

2. Cylinder A is a single acting cylinder and B is a double acting cylinder with cushioned end stops.

3. The sequence is to be initiated by a normally open momentary switch and interrupted by another normally open momentary switch.

4. Use two momentary normally open switches and one of the relays provided to form a START/STOP latching circuit for step (3) above.

5. The sequence should only start if cylinder A and B are fully retracted. Use sensors to ensure this is the case.

6. Cylinder B is to be fitted with proximity sensors onto the cylinder and cylinder A’s position is sensed by electrical limit switches (roller lever type).

7. Cylinder A is to be operated by a solenoid actuated, spring return 3/2 way directional control valve (DCV).

8. A 5/2 way double solenoid DCV is to be used for Cylinder B and the solenoids must be indirectly energised through relays.

9. Cylinder B must make a rapid return.

10. The cycle must self-repeat until interrupted by the STOP button.

WARNING: DO NOT POWER SOLENOID VALVES DIRECTLY WITH REED SWITCHES.

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Sample Tasks Automation Competition Task Descriptions

TASK C: Programing a sequence with a PLC Weighting (points out of total): 40 / 100 Maximum time allowed, t max: 60 minutes Problem: Use Festo TP101 and TP201 equipment set along with your PLC to design, assemble and commission an electro-pneumatic circuit with the following sequence:

( ) úû

ùêë

é-+--÷÷

ø

öççè

æ++ 2,,2,,2,,2, BBsBsAs

BA

Circuit requirements:

1. Adjust the supply pressure to 6.0 bars.

2. Cylinders A and B are double acting cylinders with cushioned end stops.

3. The cycle is to be initiated by actuating a normally open momentary push-button switch (START). The cycle is not to self-repeat but must be able to start again by pressing the (START) button on demand, without resetting or reloading the programme to your PLC.

4. Use an appropriate solenoid actuated with spring return valve for Cylinder A and a double solenoid valve for Cylinder B.

5. Cylinder B solenoids are to be controlled indirectly using relay contacts.

6. Each cylinder is to have a sensor to detect its extended and retracted position. These can be any of the sensors available in the equipment set provided.

+++ END OF TASKS +++

Automation

Assessment Summary

Marking Criteria

Please note this is an example of how marks will be broadly awarded.

Regional Heat:

Criterion ID Criterion Description Max Marks

A TASK 1: Pneumatic sequence 30

B TASK 2: Electro-pneumatic (Hard-wired system) 30

C TASK 3: PLC programming 40

Total Marks 100

National Final:

Criterion ID Criterion Description Max Marks

A TASK 1: Pneumatic sequence I 20

B TASK 2: Pneumatic sequence II (self-repeating) 15

C TASK 3: Sequence programming with a PLC 20

D TASK 4: Electro-pneumatic (Hard-wired system) 20

E TASK 5: PLC programming 25

Total Marks 100

Aspect ID

Aspect of Criterion – Description

Max Mark Requirement or Nominal Size

Result or

Actual Value

Mark Awarded

A1 Switch air supply on and observe both cylinders in retracted position.

1.0 (0.5 per cylinder)

Cylinders retracted.

A2 Supply pressure correctly set to 5.0 bar. 0.5 5.0 bar

A3 Used two N/C 3/2 way valves with dual pressure valve to form AND logic for starting the cycle.

1.5 Starts when both

buttons are pressed.

A4 Monitor cylinder A pressure - gauge fitted to the back of cylinder

0.5 Pressure gauge

fitted

A5 Fit flow restrictor to starve Cylinder A. 1.0 Flow restrictor fitted

correctly

A6 A sensor from each cylinder is used to ensure both cylinders are retracted before cycle can start.

2.0 Sensors are part of

the starting sequence.

A7 Cylinder A controlled by 5/2 way pilot actuated and spring return DCV

1.0 5/2 way spring

return

A8 Cylinder B is to have a pilot actuated and pilot return 5/2 way DCV. 1.0

5/2 way pilot actuated and pilot

return.

A9

Observe specified sequence shown below:

B

A

bar

AsB ,

0.4,2,

12.0

Remove 2 mark for each incorrect step up to a max of 12.0

marks.

A10 Cycle runs once and comes to rest. 1.0 Cycle does not self-

repeat.

A11 Starve Cylinder A in forward direction. 0.5 Flow valve used on

Cylinder A

A12 Speed control element for Cylinder B fitted correctly.

0.5 Max force behind

piston.

A13 Cylinder B full forward stroke time. 0.5 3.0 ± 0.5s

A14 Use quick exhaust valve on Cylinder B 0.5 Cylinder B returns

fast.

A15 Pressure sequence valve set correctly. 0.5 4.0bar

A16

Time evaluation: If task completed within given time AND sequence in A9 is

correct then calculate bonus points for speed of completion the task. Points for time = (max. time – actual time) x max. points /(max. time – min. time) = (60.0 - ....... ) x 3 Points / (60.0 - ....... )

3.0

A17

Professional practice: Circuit tidiness of the tubing and layout of the order of elements and the hierarchy of the circuit devised.

3.0

30.0

Aspect ID

Aspect of Criterion – Description

Max Mark

Requirement or Nominal Size

Result or

Actual Value

Mark Awarded

B1 Supply pressure set to 5.5 bars.

1.0 5.5 bar

B2 A single acting and a double acting cylinders used.

1.0 Single and double acting cylinders.

B3 Use proximity sensors for ensuring both cylinders are retracted before the sequence starts.

2.0 Both retracted

position sensors are wired in.

B4 Cylinder A is controlled by a solenoid actuated spring return solenoid 3/2 way DCV.

1.0 Used a 3/2 way

spring return solenoid valve.

B5 Cylinder B is controlled by a double solenoid 5/2 way DCV.

1.0 Used a 5/2 way double solenoid

valve.

B6 Cylinder B solenoids are wired in indirectly through relay contacts.

2.0 Indirect wiring,

B7 Cylinder A is fitted with roller lever limit switches.

1.0 Roller limit switches

fitted.

B8 Cylinder B is fitted with magnetic pickup proximity sensors are mounted onto the cylinder body.

2.0 Reed switches

fitted

B9 Magnetic pickup sensors are passed through relay contacts.

2.0

Sensors are

passed through relays.

B10 Quick exhaust valve fitted to Cylinder B 1.5 Cylinder B returns

fast

B11 Observe specified sequence

ABAB ,,,

8.0 Remove 2 marks for each incorrect step (max of 8).

B12 Cycle starts with a N/O momentary switch. 1.0 Used momentary

switch.

B13 Cycle stops with a N/O momentary switch. 1.0 Used momentary

switch.

B14 A latching relay is used for start and stop circuit.

1.0 Used a relay.

B15 The sequence repeats itself until interrupted by the stop button.

1.5 Self-repeating

circuit.

B16 Time evaluation: If task completed within given time AND sequence in B11 is correct then

calculate bonus points for speed of completion the task. Points for time = (max. time – actual time) x max. points /(max. time – min. time) = (60.0 - ....... ) x 3 Points / (60.0 - ....... )

3.0

30.0

Aspect ID

Aspect of Criterion – Description

Max Mark

Requirement or Nominal Size

Result or Actual Value

Mark Awarded

C1 Set pressure to 6.0 bars. 1.0 6.0 bars.

C2 Both cylinders have two proximity sensors fitted to detect end of travel.

2.0 4 proximity

sensors fitted.

C3 Cylinder A is controlled by a 5/2 way solenoid actuated and spring return valve.

2.0 Y/N

C4 Cylinder B is controlled by a 5/2 way solenoid actuated and solenoid return valve.

2.0 Y/N

C5 Cylinder B solenoids are indirectly driven. 2.0

Solenoids are connected to

relay contacts.

C6 Programme the following sequence using a PLC:

2,,2,,2,,2, BBsBsAs

B

A

21.0

Deduct 3 points per step (steps

are separated by commas)

(max of 21)

C7 Cycle starts by pressing a N/O momentary switch.

2.0 Y/N

C8 The sequence repeats only once, whenever the start button is pressed, without resetting or reloading the PLC programme.

3.0 No self-repeat.

C9 Time evaluation: If task completed within given time AND sequence in C6 is correct then calculate bonus points for speed of completion the task. Points for time = (max. time – actual time) x max. points /(max. time – min. time) = (60.0 - ....... ) x 5 Points / (60.0 - ....... )

5.0

40.0

Criterion ID Criterion Description Max Marks

Total averaged mark awarded

A TASK 1: Pneumatic sequence 30

B TASK 2: Electro-pneumatic (Hard-wired system)

30

C TASK 3: PLC programming 40

Total Marks 100