FluidSIM 3.6 Hydraulics 104 0561C FL SIM H

User Manual: 104-0561C

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Contents
1 Welcome!
2 Getting Started
3 Introduction to Simulating and Creating Circuits
4 Advanced Concepts in Simulating and Creating Circuits
5 Learning, Teaching, and Visualizing Hydraulics
6 Special Functions
7 Help and Advanced Tips
- 7.1 The Most Frequently Occurring Problems
- 7.2 Tips for the Advanced User
A FluidSIM Menus
B The Component Library
C Didactics Material Survey
D Messages
Index

FluidSIM®3.6

Hydraulics

User’s Guide

648590 GB

04/04

FluidSIM®3 Hydraulics is the result of a joint research venture between

the Measuring and Control Technology Department of Duisburg

University and the Knowledge-based Systems Department of the

University of Paderborn.

Concept and development of FluidSIM®3 Hydraulics is based on

research work carried out by Dr. Daniel Curatolo, Dr. Marcus Hoffmann,

and Dr. habil. Benno Stein. Mechanical Engineering contributions by Dr.

Ralf Lemmen.

Order No.: 648590

Description: HANDBUCH

Designation: D:HB-FSH3-GB

Edition: 4/2004

Author: Art Systems

Layout: Art Systems

Internet: www.festo.com/didactic

e-mail: did@festo.com

Internet: www.art-systems.com, www.ﬂuidsim.com

e-mail: info@art-systems.com

Internet: www.eatonhydraulics.com

e-mail: HydraulicsTraining@eaton.com

The copying, distribution and utilization of this document as well

as the communication of its contents to others without expressed

authorization is prohibited. Offenders will be held liable for the payment

patent, utility model or ornamental design registration.

Contents

1. Welcome! 7

1.1 About FluidSIM 8

1.2 Layout of the Handbook 9

1.3 Conventions 10

2. Getting Started 11

2.1 Technical Requirements 11

2.2 Installation 11

2.2.1 Installation with Program Activation 11

2.2.2 Installation with license connector 12

2.3 Supplied Files 15

2.4 De-installation of a Single-Position License 17

3. Introduction to Simulating and Creating Circuits 18

3.1 Simulating Existing Circuit Diagrams 21

3.2 The Different Simulation Modes 28

3.3 Creating new Circuit Diagrams 29

4. Advanced Concepts in Simulating and Creating Circuits 46

4.1 Additional Editing Functions 46

4.2 Additional Simulation Functions 56

4.3 Linking Components Automatically 58

4.4 Current Path Numbering and Switching Elements Table 58

4.5 Displaying Quantity Values 59

4.6 Displaying State Diagrams 62

4.7 Superﬁcial Circuit Checking 64

4.8 Coupling Hydraulics, Electrics and Mechanics 66

4.9 Operating Switches 72

4.10 Adjustable Components 76

4.11 Settings for Simulation 77

4.12 OPC and DDE communication with Other Applications 80

4.13 Settings for the OPC/DDE communication 82

5. Learning, Teaching, and Visualizing Hydraulics 84

5.1 Information about Single Components 85

5.2 Selecting Didactics Material from a List 91

5.3 Presentations: Combining Instructional Material 98

5.4 Extended Presentations in the Microsoft PowerPoint Format 102

5.5 Playback of Educational Films 105

Contents

5.6 Settings for Didactics 107

6. Special Functions 109

6.1 Drawing Layers 109

6.2 Graphic Primitives 110

6.3 Text Components and Identiﬁcations 114

6.4 Parts Lists 116

6.5 Printing a Window’s Contents 120

6.6 DXF Export 122

6.7 DXF Import 123

6.8 Using and Organizing Component Libraries 126

6.9 Managing Projects 134

6.10 Saving Settings 136

7. Help and Advanced Tips 139

7.1 The Most Frequently Occurring Problems 139

7.2 Tips for the Advanced User 144

A. FluidSIM Menus 149

A.1 File 149

A.2 Edit 151

A.3 Execute 153

A.4 Library 154

A.5 Insert 155

A.6 Didactics 155

A.7 Project 157

A.8 View 158

A.9 Options 161

A.10 Window 163

A.11 ? 163

B. The Component Library 164

B.1 Hydraulic Components 165

B.2 Electrical Components 179

B.3 Electrical Components (American Standard) 188

B.4 Digital Components 192

B.5 Miscellaneous 203

C. Didactics Material Survey 205

C.1 Basics of Hydraulics 206

4 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

Contents

C.2 Components of a Hydraulic Plant 207

C.3 Symbols 210

C.4 Some Physical Fundamentals 215

C.5 Components of a Power Unit 219

C.6 Fundamentals of Valves 223

C.7 Pressure Valves 226

C.8 Way Valves 234

C.9 Shutoff Valves 244

C.10 Flow Valves 248

C.11 Hydraulic Cylinders and Motors 252

C.12 Gauges 255

C.13 Exercises 256

C.14 Extensions 269

C.15 Educational Films 270

C.16 Standard Presentations 271

D. Messages 272

D.1 Electrical Errors 272

D.2 Drawing Errors 272

D.3 Operating Errors 274

D.4 Opening and Saving Files 275

D.5 System Errors 276

Index 278

Contents

6 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

1. Welcome!

Welcome to FluidSIM !

Thank you for purchasing the FluidSIM®3 Hydraulics training software.

This handbook functions both as an introduction to FluidSIM and as a

reference manual outlining the possibilities, concepts, and operation of

the software package. This handbook, however, is not intended to help

in deﬁning special aspects of hydraulics. Concerns of this nature can be

found in the Festo Didactic GmbH & Co. KG textbook series.

Users of this software are encouraged to contribute tips, criticism, and

suggestions for improvement of the program via email at

info@ﬂuidsim.com

did@festo.com

Moreover, the newest updates can be found at our Internet site at

www.ﬂuidsim.com

www.festo.com/didactic

April 2004 The Authors

1. Welcome!

1.1

About FluidSIM

FluidSIM®3 Hydraulics is a teaching tool for simulating hydraulics basics

and runs using Microsoft Windows®. It can be used in combination

with the Festo Didactic GmbH & Co. KG training hardware, but also

independently. FluidSIM was developed as a joint venture between the

University of Paderborn, Festo Didactic GmbH & Co. KG, and Art Systems

Software GmbH, Paderborn.

A major feature of FluidSIM is its close connection with CAD functional-

ity and simulation. FluidSIM allows DIN-compliant drawing of electro-

hydraulic circuit diagrams and can perform realistic simulations of the

drawing based on physical models of the components. Simply stated,

this eliminatesthe gap between the drawing of a circuit diagram and the

simulation of the related hydraulic system.

The CAD functionality of FluidSIM has been specially tailored for ﬂuidics.

For example,

while drawing

, the program will check whether or not

certain connections between components are permissible.

Another feature of FluidSIM results from its well thought-out didactic

concept: FluidSIM supports learning, educating, and visualizing

hydraulic knowledge. Hydraulic components are explained with textual

descriptions, ﬁgures, and animations that illustrate underlying working

principles; exercises and educational ﬁlms mediate knowledge about

both important circuits and the usage of hydraulic components.

The development of FluidSIM included special emphasis on both an

intuitive and easy-to-learn user interface. The user will quickly learn to

draw and simulate electro-hydraulic circuit diagrams.

8 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

1. Welcome!

1.2

Layout of the Handbook

The Handbook from FluidSIM has been divided into two parts. The

ﬁrst part serves as a user’s guide, and the second part functions as

a reference book. The user’s guide contains chapters that introduce

the user to FluidSIM. By following the chapters in order, the user will

understand how to operate FluidSIM. The reference part contains a

complete listing of the FluidSIM functions, the component library, the

didactics material, and the FluidSIM messages.

User’s Guide Chapter 2describes the computer requirements for FluidSIM, the

installation process, and the meaning of the supplied ﬁles.

Chapter 3contains small examples of circuit diagrams, showing how

they can be simulated and how new circuit diagrams can be created.

Chapter 4introduces advanced concepts of FluidSIM. Examples include

the linking of hydraulic and electric components, the possible settings

for simulation, and the testing of a circuit diagram.

Chapter 5shows additional educational concepts. In particular, FluidSIM

enables a user to pop-up a component’s technical description, to start

animations, or to play a ﬁlm with related information.

Chapter 6describes special functions of FluidSIM including how to

print and export circuit diagrams, along with the rearrangement of the

component library.

Chapter 7deals speciﬁcally with help for questions concerning the use

of FluidSIM. It also includes tips for the advanced user.

Reference Appendix Acontains a complete listing of FluidSIM menus and is

intended to be used as a quick reference for all FluidSIM functions.

Appendix Bcontains the library of all FluidSIM components.

1. Welcome!

Appendix Ccontains the component illustrations, the animations, the

exercises, and the educational ﬁlms.

Appendix Dcontains a listing of messages that may occur while using

FluidSIM along with a brief explanation for each.

1.3

Conventions

User instructions are indented and marked with the >arrow; important

passages begin with the ☞symbol.

The symbols found on the FluidSIM toolbar are represented in this

manual with the appropriate icon; menu entries are shown framed ;

function keys are represented with their appropriate key symbol. For

example is the icon used to start a simulation; File Open... indicates

the “Open...” entry under the “File” menu; F9 stands for function key

“9”.

In this manual the term “clicking” with a mouse means using the left

mouse button. It is explicitly stated when the right button is to be used.

Values for quantities calculated and displayed in FluidSIM are expressed

in the following units:

Quantity Unit of measure

Pressure (p) bar, MPa

Flow (q) l/min

Velocity (v) m/s

Force (F) N

Opening level (%) -

Voltage (U) V

Current (I) A

10 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

2. Getting Started

This Chapter describes how FluidSIM is installed on your computer.

2.1

Technical Requirements

You need a computer with a Pentium processor or higher that runs

using Microsoft Windows9x®, Microsoft WindowsME®,MicrosoftWin-

dowsNT®, Microsoft Windows2000®or Microsoft WindowsXP®.

If you intend to draw simple circuit diagrams or to simulate the existing

circuit diagrams, 64 MB RAM is adequate. However, minimum 128 MB

RAM is recommended to simulate complex circuit diagrams.

In order to play the educational ﬁlms, you will need a CD-ROM drive that

runs at double speed along with hardware for sound.

2.2

Installation

When you purchased FluidSIM, you received a CD and possibly a

license connector . Aside from the educational ﬁlms, the CD contains

both the full version and the student version of FluidSIM.

The installation procedure is described in the following sections.

The full version of FluidSIM is available in two versions: A version that

supports the automatic online activation and the license connector

version.

2.2.1

Installation with Program

Activation

With the ﬁrst start of FluidSIM you will be asked to activate FluidSIM.

The activation follows one of the following three variants.

• Automatic Online Activation

This variant requires Internet access from the computer where

FluidSIM is to be activated and realizes a completely automated

procedure.

• Indirect Activation

In this variant an activation dialog box is opened that shows an

Internet address (url) and your individual license ID. With this

information you can generate your individual activation key at an

arbitrary computer with Internet access. Then, the activation key

has to be entered in the activation dialog box of the installation PC.

2. Getting Started

• Call Festo to receive your individual activation key

If you don’t have Internet access or if the Internet activation fails,

you can call a service employee at weekday ofﬁce hours who will

provide you with your activation code.

2.2.2

Installation with license

connector

Depending on the license model (single-position systems or network),

the license connector is needed only during the

Installation

of FluidSIM

or must be attached to the so-called

license server

The

blue

license connector for single-position systems deﬁnes how

many times FluidSIM can be installed. If, for instance, you have bought

a classroom license, exactly the corresponding number of single-

position installations can be performed. Note, however, that by each

de-installation the license connector can be “recharged” by simply

connecting it and starting the de-installation program (see section 2.4).

The

green

network license connector deﬁnes how many instances of

FluidSIM can be running at the same time in the network. If you attempt

to start more instances than the allowed number, an error message is

displayed. If the license server is down or if the license connector has

been removed from the system, all circuits that are already open and

modiﬁed can be saved before FluidSIM terminates. If the license server

is up again FluidSIM starts as usual.

FluidSIM Full Version:

Installation from CD

> If you purchased a version with single-position license connector,

make sure that your computer is switched off and attach the license

connector to the parallel interface (LPT 1) of your PC.

Often there is a printer attached to the computer. The printer cables

must be removed while installing FluidSIM.

> Turn the computer on and start Microsoft Windows®.

>InserttheCD.

12 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

2. Getting Started

> Click Run... in the Start Menu.

A dialog box opens.

> Enter the following string in the space provided: d:setup.exe.

Then click “OK”.

If your CD-ROM drive is conﬁgured differently, then be sure to use

the appropriate letter in place of d:.

After a few seconds the startup screen of the installation program

appears. Here you can choose whether to install the student version

or the full version of FluidSIM. When installing the full version, please

select the appropriate license connector (single-position systems or

network). If you got a FluidSIM version for online activation no license

connector is necessary but only your individual product ID is required,

which is printed on the back of the CD cover. Note that the student

version does neither require a license connector nor a product ID.

> Follow the directions as they appear on the screen. If you are

unsure how to answer or are unsure of a question, simply click

“Next >>”.

Note that with each start of FluidSIM the user name appears. Also note

that the company’s name is stored in the license connector.

Import Online Activation

Notes

During the activation of FluidSIM several features of your PC and the

product ID are used to generate an individual license ID. This string is

validforyourPConly.I.e.,ifyourPCissubstantiallymodiﬁedorifyou

want to use another PC, your FluidSIM license has to be transfered to

the new hardware. This happens automatically, if you again activate

FluidSIM when starting the program with the new hardware.

Note that reactivation means license transferral: After a reactivation on

a new hardware FluidSIM cannot be activated again on the original PC.

2. Getting Started

Blue License Connector for

Single-Position

Systems—Important

Usage Notes

To avoid a mistakenly loss of your licenses, please consider the

following tips:

• Modiﬁcation of the system conﬁguration

De-install FluidSIM temporarily before you modify the system

conﬁguration (exchange of hardware components, re-installation

of the operating system).

•Temporaryde-installation of FluidSIM

When temporarily de-installing FluidSIM, modiﬁed and newly

created ﬁles can be preserved. A subsequent re-installation of

FluidSIM will recognize these ﬁles.

• Hard disk failure

In the case of a hard disk failure Festo Didactic GmbH & Co. KG will

help to reactivate your FluidSIM license if you own a backup of the

hard disk (phone: 0049-711-3467-0).

14 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

2. Getting Started

2.3

Supplied Files

The directory structure of FluidSIM is demonstrated in the following

ﬁgure.

The directory aq contains the knowledge bases for FluidSIM.

The directory bin contains the executable FluidSIM program along with

additional libraries.

This directory also contains the registration information and the

program fduninst.exe, which is necessary for de-installation.

You should not make any changes to this directory bin.

The directory bmp4 contains the photos of components in the compo-

nent library. These pictures have four gray scales for use with Microsoft

Windows®with sixteen colors.

2. Getting Started

The directory bmp16 also contains the photos of components in the

component library. These pictures have sixteen gray scales for use with

Microsoft Windows®with at least 256 colors.

The directory bmp16c contains the ﬁgures of both the component

illustrations and the didactics material.

The directory ct contains the supplied circuits for FluidSIM. This is also

the default directory in which all new circuits diagrams are saved. In its

subdirectories the following circuit diagrams have been included:

shows: Circuits that can be opened as a bitmap via the Didactics

menu (see section 5).

tp501: Circuits in the workbook “Hydraulics Basic Level TP 501”.

tp502: Circuits in the workbook “Hydraulics Advanced Level TP

502”.

tp601: Circuits in the workbook “Electro-hydraulics Basic Level TP

601”.

tp602: Circuits in the workbook “Electro-hydraulics Advanced

Level TP 602”.

The directory lib contains the component library of FluidSIM as total

view.

The directory lib2 contains the component library of the versions 2.x of

FluidSIM.

The directory misc contains auxiliaryﬁles and option ﬁles for FluidSIM.

The directory snd contains sound ﬁles for FluidSIM.

The directory sym shows the component library of FluidSIM as a

hierarchical view. In the same hierarchical fashion the contents of this

directory is also shown in the menu Insert .

The directory shw contains ﬁles for use with presentations.

16 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

2. Getting Started

The directory ppx contains extended PowerPoint presentations.

The directory tmp contains the pre-calculated circuit models and

temporary ﬁles created by FluidSIM.

The complete FluidSIM software takes up approximately 16 MB of

memory on the hard disk.

2.4

De-installation of a

Single-Position License

The following steps are necessary to de-install FluidSIM from your

computer.

> Connect the blue license connector to the parallel port (LPT 1).

> Click on the program icon Remove FluidSIM-H in the Start

Menu Program Files/Festo Didactic.Iftheprogramicon

cannot be found, start the program fduninst.exe in the bin-

subdirectory of the FluidSIM directory.

The license connector will charge and you will be asked whether or not

you would like to preserve user-modiﬁed ﬁles.

> You should answer “Yes”, if you would like to keep the ﬁles that

you created with FluidSIM, for example new circuit diagrams and

presentations, and also information that you changed while using

FluidSIM. When re-installing FluidSIM, you should use the same

directory path.

You should answer “No”, if you want to completely remove FluidSIM

from your computer.

If a problem occurs during de-installation, do not attempt to manually

change or delete FluidSIM. Instead report problems and errors to Festo

Didactic GmbH & Co. KG (phone: 0049-711-3467-0).

3. Introduction to Simulating and Creating Circuits

The following chapter is set up in the form of a tutorial to introduce the

user to important FluidSIM functions. At the end the user should be

comfortable designing and simulating circuit diagrams.

> Start FluidSIM via the Start Menu under Program Files/

Festo Didactic.

After a few seconds the main window from FluidSIM should appear on

your screen:

18 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

3. Introduction to Simulating and Creating Circuits

The left-hand side shows the component library of FluidSIM in its total

view; it contains hydraulic and electrical components for the creation

of new circuit diagrams. The menu bar at the top of the window lists all

the functions needed for the simulation and creation of circuit diagrams.

The toolbar beneath this menu displays frequently used menu functions.

The toolbar contains the following nine groups of functions:

creating new circuit diagrams, previewing a circuit diagram, opening

and saving circuit diagrams

printing the contents of the window, for example circuit diagrams

and component photos

editing circuit diagrams

alignment of components

using a grid

zooming in and zooming out of circuit diagrams, component

pictures, and other windows

superﬁcial circuit checking

simulating circuit diagrams, directing animation (basic level)

simulating circuit diagrams, directing animation (additional

functions)

3. Introduction to Simulating and Creating Circuits

Only a certain number of the above listed functions will apply to a

speciﬁc circuit diagram. FluidSIM recognizes which functions apply

according to the contents of the window, component functions and

context (circuit diagram design, animation, circuit diagram simulation,

etc.), and disables the operations on the toolbar that do not apply.

In many new Microsoft Windows®programs “context menus” are

available. A context menu appears when the user clicks the

right

button

on the mouse within the program window. In FluidSIM, context menus

apply to the contents and situations in the window; the context menus

contain a useful subset of functions from the main menu bar.

Located at the bottom of the window is a status bar that displays

information on the current calculations and activities during the

operation of FluidSIM. In Edit Mode, FluidSIM displays the designation

of the component found under the mouse cursor.

Buttons, scrollbars, and the menu bar in FluidSIM operate in the same

way as in most other programs that utilize Microsoft Windows®.

20 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

3. Introduction to Simulating and Creating Circuits

3.1

Simulating Existing

Circuit Diagrams

Included with the FluidSIM installation disks are a number of working

circuit diagrams. The circuit diagrams will be utilized in the following

sections as demonstration and learning material. A more detailed

description of the circuits can be found in the following workbooks

“Hydraulics Basic Level TP 501”, “Hydraulics Advanced Level TP

502”, “Electro-hydraulics Basic Level TP 601”, and “Electro-hydraulics

Advanced Level TP 602”.

These circuit diagrams can be opened and simulated with FluidSIM as

follows:

> Click on or choose Circuit Preview in the File menu.

3. Introduction to Simulating and Creating Circuits

Preview windows containing overviews of existing circuit diagrams

should appear:

Apreview window displays the circuit diagrams of a speciﬁc directory

in alphabetical order accompanied by a miniature representation. The

name of the current directory is shown in the title bar of the preview

window; the ﬁles of the FluidSIM circuit diagrams contain the extension

ct.

22 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

3. Introduction to Simulating and Creating Circuits

By double clicking a directory icon you go down to the respective

subdirectory.

In the ct subdirectory of the fl_sim_h installation additional

subdirectories for diagrams can be created. These subdirectories are

automatically found by FluidSIM, and extra directory icons are created

for them.

>Openthecircuitdiagramdemo1.ct by double clicking on its

miniature representation.

Circuit diagrams can also be opened using the File Selector dialog box.

By clicking on or choosing Open... under the File menu, the File

Selector dialog box will appear, in which a circuit diagram can be opened

by double clicking on its ﬁlename.

3. Introduction to Simulating and Creating Circuits

In either case the circuit diagram is opened and displayed in a new

window:

> Click on or on Execute Start ,orpressthekey F9 .

FluidSIM switches to the

simulation mode

and starts the simulation of

the circuit diagram. When in the simulation mode, the mouse cursor

changes to a hand .

During the simulation FluidSIM ﬁrst calculates all electrical parameters.

This step is followed by formulating the model of the hydraulic circuit,

and, based on the model, the entire distribution for ﬂow and pressure is

calculated.

24 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

3. Introduction to Simulating and Creating Circuits

Formulating models is demanding. Depending on a circuit’s complexity

and the computer’s power, a circuit’s simulation may take considerable

time.

As soon as the results are available, the connection lines will be shown

in color and the cylinders extend in sequence:

The colors of the connection lines have the following meaning:

Color Meaning

Dark red Hydraulic line: pressure ≥50%ofmaximum

Ocher Hydraulic line: pressure <50%ofmaximum

Light red Electrical line, current ﬂowing

3. Introduction to Simulating and Creating Circuits

You can deﬁne your own mapping between colors and state values

under Options Simulation... . The varying thicknesses of the

dark red

connection lines corresponds to the pressure as related to the maximum

pressure. FluidSIM distinguishes between three thicknesses of line:

Thickness Meaning

Pressure ≥50%and<75%ofmaximum

Pressure ≥75%and<90%ofmaximum

Pressure ≥90%ofmaximum

The exact numeric values for pressures, ﬂow rates, voltages, and

currents are displayed on the attached measuring instruments.

Section 4.5 describes how you may go about getting values for all or

only selected variables on the circuit diagram, even when measuring

instruments are not present.

Simulation in FluidSIM is based on physical models whose components

match those components found in the Festo Didactic GmbH & Co. KG

equipment set. Therefore, calculated values should closely match

measured values. When comparing results, please acknowledge the

fact that in practice, measurements can be subject to large ﬂuctuations.

The reasons for differences range from component tolerances to oil

temperature.

The calculation of variables forms the basis for an exact,

real-time

proportional

animation of the cylinder.

Real-time-proportionality guarantees the following property: If in reality

a cylinder moves twice as fast as another one, the relationship between

these two components is shown in the animation. In other words, the

real-time relationship remains unaltered.

Manually operated valves and switches, found in the circuit diagram,

can be switched by clicking on them with the mouse:

26 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

3. Introduction to Simulating and Creating Circuits

> Move the mouse cursor to the left switch.

The mouse cursor becomes a hand with index ﬁnger and indicates

that the switch may be ﬂipped.

> Click on the switch.

When you click on a manually operated switch, its real behavior is

simulated. In this example the clicked switch becomes closed and

recalculation begins automatically. Following the calculation, the new

pressure and ﬂow values are indicated and the cylinders retract.

The switching of a component is only possible when a simulation is

running ( ) or when a simulation has been set to pause ( ).

In the event that you would like to simulate another circuit diagram,

it is not necessary to close the open one. FluidSIM allows you to have

several circuits open at one time. Furthermore, FluidSIM is able to

simulate multiple circuits simultaneously.

> Click on or Execute Stop to switch the current circuit from

Simulation Mode to Edit Mode.

By switching a circuit from Simulation Mode to Edit Mode, all compo-

nents will automatically be set back to their “normal status”. In partic-

ular, switches are set to their original position, valves switch to their

normal position, cylinder pistons are set to their

position, and

all values calculated are deleted.

By clicking on (alternative: Execute Pause or F8 ) you can switch from

Edit Mode to Simulation Mode without starting the simulation. This

feature is useful, if components shall be set

before

the simulation is

started.

3. Introduction to Simulating and Creating Circuits

3.2

The Different Simulation

Modes

In addition to the functions of the preceding section ( ,,), there

exist also the following additional functions:

reset and restart of the simulation

simulation in single step mode

simulation to a certain point where a state change happens

Reset and Restart of the

Simulation

By clicking on or under Execute Reset , an already running simulation

or paused simulation can be reset. Immediately following this, the

simulation will be restarted.

Single Step Mode During single step mode, the simulation will stop after a small step.

More exactly, by clicking on or Execute Single Step , the simulation will

begin for just a short time period (approximately 0.01 - 0.1 seconds in

the real system); the system then pauses ( ).

A running simulation can, at any time, be set into single step mode. It is

then possible to focus on key moments during the simulation.

Simulation to a State

Change

By clicking on or under Execute Simulate until State Change the

simulation begins and runs up until a certain point where a state change

happens; the simulation then pauses ( ). The following situations

describe the point at which the simulation pauses:

1. a cylinder’s piston moves at a stop

2. a valve switches or is operated

3. a relay switches

4. a switch is operated

It is possible to switch from a running simulation into this state change

mode.

28 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

3. Introduction to Simulating and Creating Circuits

3.3

Creating new Circuit

Diagrams

This section contains an introduction to creating and simulating circuit

diagrams using FluidSIM.

> Create an empty drawing area by clicking on or under File New

to open a new window:

Circuit diagrams can only be created or altered in the Edit Mode. The

Edit Mode is indicated with the following mouse cursor .

3. Introduction to Simulating and Creating Circuits

Each and every newly opened drawing area automatically contains a

name, with which it can be saved. This name is found in the title bar of

the new window.

Using the scrollbars found to the right of and underneath the component

library, you can scroll through the components. Using the mouse, you

can “drag” and “drop” components from the component library onto the

drawing area:

> Move the mouse cursor to a component in the library, more

speciﬁcally to the cylinder.

> Press the left mouse button. While continuing to hold down the

button, move the cursor.

The cylinder is then

highlighted

(selected) and the mouse cursor

changes to a four way directional cross . The component’s outline

moves with the mouse cursor.

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3. Introduction to Simulating and Creating Circuits

> Move the cursor to the drawing area and release the button on the

mouse. This action places the cylinder in the drawing area:

In this way it is possible to “drag” each component from the component

library and place it in the desired position in the drawing area. In the

same way it is possible to rearrange components already in the drawing

area.

> Drag the cylinder to the bottom right hand corner.

In order to simplify the creation of circuit diagrams, the components

automatically snap to grid in the drawing area.

> Try to move the cylinder onto a non-permissible area, for example

outside the window.

3. Introduction to Simulating and Creating Circuits

Outside a permissible area the mouse cursor changes to the prohibited

sign ; the component cannot be dropped.

> Drag a second cylinder onto the drawing area and notice that the

second cylinder is now highlighted.

> Highlight, say, select the ﬁrst cylinder by clicking on it.

> Delete the cylinder by clicking on (cut) or under Edit Delete or by

pressing the Del key.

The commands in the Edit menu correspond only to the selected

components.

> Drag onto the drawing area a conﬁgurable 4/n-way valve, a pump

unit, and a tank.

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3. Introduction to Simulating and Creating Circuits

> Arrange the components in the following manner:

3. Introduction to Simulating and Creating Circuits

Double click the valve to assign an operation mode to it. A dialog box

appears:

Description of the dialog box:

• “Left/Right Actuation”

For both sides the actuation modes of the valve can be deﬁned

individually; it can be one or more of the categories “manual”,

“mechanical”, or “hydraulic/electrical”. An operation mode is set

by clicking on the down-arrow at the right-hand side of the list and

selecting a symbol. If for a category no operation mode is desired,

simply choose the blank symbol from the list. Moreover, for each

side of the valve the attributes “spring-returned” and “piloted” can

be set.

•“Description”

Enterhereanameforthevalve.Thisnameisusedinthe

state diagram and in the parts list.

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3. Introduction to Simulating and Creating Circuits

•“ValveBody”

A conﬁgurable valve has at most four positions. For each of the

positions a valve body element can be chosen individually. Such

an element is set by clicking on the down-arrow at the right-hand

side of the list and selecting a symbol. If for a position no element is

desired, simply choose the blank symbol from the list.

• “Initial Position”

This button deﬁnes the valve’s initial position (sometimes also

called normal position or neutral position), which is the position

without having any operation applied to the valve. Note that this

setting is only exploited if it physically does not contradict a spring-

returned setting, possibly deﬁned above.

> Choose from the left-hand side in the topmost list a manual

operation with snap in, and select the “spring-returned” option

in the right ﬁeld. Close the dialog box via OK.

Now the valve should look as follows:

> Move the mouse cursor over the left cylinder

connection

In Edit Mode, the mouse cursor changes to a cross-wires pointer ,

when it is above a component

connection

> Press the left mouse button while the mouse cursor is above the

cylinder connection. Move the mouse cursor and notice how the

cross-wires pointer gains arrows .

3. Introduction to Simulating and Creating Circuits

> Keep pressing the mouse button, and move the cross-wires pointer

to the upper left valve connection. Notice how the arrows on the

cross-wires pointer turn inward .

> Release the mouse button.

Immediately a line appears between the two chosen connections:

FluidSIM automatically draws a line between the two chosen connec-

tions. The mouse cursor changes to the prohibited sign when it is

not possible to draw a line between two connections.

> Move the mouse cursor to a line.

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3. Introduction to Simulating and Creating Circuits

In the Edit Mode, the mouse cursor changes to a line-selection symbol

, when it is positioned over a line.

> Press the left mouse button and move the line-selection symbol to

the left. Release the mouse button.

Immediately, the line is redrawn:

In the Edit Mode the components and lines can be selected, moved, or

deleted by clicking on Edit Delete or by pressing the Del key.

> Connect the remaining components.

3. Introduction to Simulating and Creating Circuits

The circuit diagram should look somewhat like the following one:

The circuit diagram has been completely drawn and connected. Attempt

to simulate this circuit.

> Start the simulation by clicking on (or under Execute Start or

with the F9 key).

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3. Introduction to Simulating and Creating Circuits

During simulation all pressures and ﬂow rates are calculated, all lines

are colored, and the cylinder’s piston extends.

After the cylinder has been extended, the pressure in the cylinder supply

line must inevitably increase. This situation is recognized by FluidSIM

and the parameters are recalculated; the pressure downstream of the

pump unit increases to the value, as deﬁned by the pump unit safety

guard.

In order to keep the value of the maximum pressure low, the pump unit

must be equipped with a pressure relief valve.

> Activate the Edit Mode by clicking on (or under Execute Stop or

with the F5 key).

3. Introduction to Simulating and Creating Circuits

> Drag a pressure relief valve and a second tank into the window.

In reality, to connect a component to an existing line requires a T-

connection . FluidSIM automatically creates a T-connection when you

draw a line from a connection to an existing line.

> Using the cross-wires cursor draw a line between the input

connection of the pressure relief valve to the line connecting the

pump unit and the valve. Notice how the arrows in the cross-wires

turn inwards .

> Release the mouse button.

The T-connection appears on the line at the point where the mouse

button was released.

> Connect the tank to the pressure relief valve.

> When possible, draw the line so that the wiring diagram is arranged

clearly.

40 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

3. Introduction to Simulating and Creating Circuits

The circuit diagram should now appear somewhat like the following

diagram:

> Save the circuit by clicking on or File Save . FluidSIM automati-

cally opens the File Selector dialog box, if the title is new; here you

must give the circuit a name.

> Start the simulation by clicking .

3. Introduction to Simulating and Creating Circuits

The cylinder’s piston extends. As soon as the piston fully extends, a

new situation arises. This situation is recognized by FluidSIM and is

recalculated. The pressure relief valve opens and the distribution of

pressure is shown:

FluidSIM not only animates manually operated components during

changeover, but nearly all components with multiple states.

The following ﬁgure shows a pressure relief valve in closed and open

position:

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3. Introduction to Simulating and Creating Circuits

Recall that in the Simulation Mode, manually operated valves and

switches can be switched with a mouse click:

> Move the mouse cursor over the left-hand side of the valve.

The mouse cursor becomes a hand with an extended index ﬁnger and

indicates that the valve can be switched.

> Click on the left side of the valve and hold the mouse button down.

When you click on a valve, the real behavior of the valve is simulated.

In our example the valve is switched to crossover position and a

recalculation is initiated automatically. As a result, the pressure relief

valve closes and the cylinder retracts. As soon as the cylinder reaches its

left stop, the pressure relief valve opens again.

Components whose switching status is not locked remain activated as

long as the mouse button is held down.

> Stop the simulation, which also brings you to Edit Mode. Select

from the component library the state diagram component, and

place it onto the drawing area.

The state diagram records the state quantities of important components

and depicts them graphically.

> Move the state diagram to a free place in the drawing. Drag the

cylinder and drop it onto the state diagram.

3. Introduction to Simulating and Creating Circuits

> Start the simulation and observe the state diagram.

Note that several state diagrams can be used in the same circuit;

however, several components may also share the same state diagram.

A component is added by simply dropping it onto the state diagram.

If a component is dropped a second time on the diagram, it will be

removed from there. State quantities of the following components can

be recorded and displayed in the state diagram:

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3. Introduction to Simulating and Creating Circuits

Component State

Cylinder Position

Way valve Position

Manometer Pressure

Flow meter Flow

Pressure or switching valve State

Switch State

The example is now ﬁnished. Further editing and simulation concepts

are described in the next chapter.

4. Advanced Concepts in Simulating and Creating

Circuits

This chapter contains advanced concepts and functions, which can be

used when simulating and creating circuits with FluidSIM.

4.1

Additional Editing

Functions

In addition to the commands that were introduced in section 3.3,the

Edit Mode in FluidSIM provides you with a higher level of important

editing functions:

Setting the Paper Size In Edit Mode the size of the paper is indicated by a red rectangle. The

default setting of the paper size is “DIN A4, portrait”. The default setting

can be changed in the menu File Drawing Size... .

The size and the orientation of the paper can be set here. If the drawing

size exceeds the paper size of your printer, the total area of several

smaller papers can be tiled with the drawing.

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4. Advanced Concepts in Simulating and Creating Circuits

For orientation purposes, under File Properties... additional information

can be stored along with each drawing. The text that is entered in

description is shown in the preview window below the respective

diagram.

Undoing Editing Steps By clicking on or Edit Undo and with Edit Redo , each step given in

the Edit Mode can be undone in the following manner:

By clicking on (Edit Undo ), the last editing step that was taken

is undone. FluidSIM recalls the last 128 editing steps, which can be

undone.

The function Edit Redo serves as a way to “withdraw the last undone

step”. When using to undo an editing step, you may go to far. By

clicking under Edit Redo , the circuit is returned to its original state

before undo was initiated. The function Edit Redo can be invoked

until there are no more undo steps to be redone.

The function Edit Undo applies to all possible editing steps in the Edit

Mode.

Multiple Selection A component can be highlighted, that is to say selected, by clicking on it

with the left mouse button. However, by clicking on another component

with the left mouse button, the ﬁrst component is no longer selected,

but the second component is. Only

one

component at a time may be

selected when clicking with the left mouse button.

4. Advanced Concepts in Simulating and Creating Circuits

If, while you are clicking on components, you hold down the Ctrl key,

the components that are already selected will remain so. In addition,

the component underneath the mouse cursor will also be selected, if not

already selected, or de-selected, if already selected. In this sense, the

component’s state of selection is reversed.

Another efﬁcient concept for selecting multiple components is by using

the

rubber band

. The rubber band is opened by pressing and holding

down the left mouse button, and then moving the mouse cursor. The

mouse cursor cannot be located directly over a component if the rubber

band shall be opened.

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4. Advanced Concepts in Simulating and Creating Circuits

All components enclosed, either partially or fully, by the rubber band,

are selected.

All components and lines of the current circuit diagram can be selected

by clicking under Edit Select All or typing Ctrl A.

Editing functions such as dragging or moving, copying and, deleting

apply to all selected components.

4. Advanced Concepts in Simulating and Creating Circuits

Right Mouse Button When you click the mouse button on the right in a FluidSIM window,

the appropriate context menu is opened. If the mouse cursor is located

above a component or component connection, the item will become

selected. If this component was not yet selected, then a possibly

existing selection of other components will be de-selected.

Clicking the right mouse button on a component (connection) is actually

a short cut for the following two actions: Clicking the left mouse button

on the component (connection) and opening a menu.

Double Clicking with the

Mouse

Double clicking the left mouse button on a component (connection)

is a short cut for the following two actions: Selecting the component

(connection) and clicking on Edit Properties... .

Copying Selected components can be copied to the clipboard by clicking on

or Edit Copy ; the component can then be inserted in the circuit diagram

by clicking on or Edit Paste . In the same way it is possible to paste

the contents of the clipboard into another graphic or word processing

program.

Within a circuit diagram selected components can also be copied by

holding down the Shift key and moving them. The mouse cursor

changes then to the copy symbol .

Copying between Windows Components can simply be copied between windows by selecting the

desired components and dragging them in the other window.

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4. Advanced Concepts in Simulating and Creating Circuits

Aligning Objects To align objects, ﬁrstly select these objects and then click on the icon

or on the appropriate entry in the Edit Align menu.

Reference object is always the object which lies furthermost in the

desired direction. If, for instance, several components shall become

aligned left, all but one objects are moved to the left so that they align

with the left-most object. Note that hydraulic and electrical components

obey the constraint that their connections must lie on the grid. As a

consequence, an alignment may not always coincide with the symbol

bounding.

Rotation Selected components can be rotated by 90°, 180° or 270°. There is a

short cut for rotating a

single

component in steps of 90° : pressing the

Ctrl key and double clicking on the component.

Deleting Lines If only one component

connection

is selected, its connected (but de-

selected) lines can be deleted using Edit Delete or by pressing the Del

key. This concept provides an alternative way to delete lines.

4. Advanced Concepts in Simulating and Creating Circuits

Conﬁguring Way Valves The body of a valve or its operation concept can be changed by double-

clicking the valve. The following dialog box is opened.

Description of the dialog box:

• “Left/Right Actuation”

For both sides the actuation modes of the valve can be deﬁned

individually; it can be one or more of the categories “manual”,

“mechanical”, or “hydraulic/electrical”. An operation mode is set

by clicking on the down-arrow at the right-hand side of the list and

selecting a symbol. If for a category no operation mode is desired,

simply choose the blank symbol from the list. Moreover, for each

side of the valve the attributes “spring-returned” and “piloted” can

be set.

•“Description”

Enterhereanameforthevalve.Thisnameisusedinthe

state diagram and in the parts list.

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4. Advanced Concepts in Simulating and Creating Circuits

•“ValveBody”

A conﬁgurable valve has at most four positions. For each of the

positions a valve body element can be chosen individually. Such

an element is set by clicking on the down-arrow at the right-hand

side of the list and selecting a symbol. If for a position no element is

desired, simply choose the blank symbol from the list.

• “Initial Position”

This button deﬁnes the valve’s initial position (sometimes also

called normal position or neutral position), which is the position

without having any operation applied to the valve. Note that this

setting is only exploited if it physically does not contradict a spring-

returned setting, possibly deﬁned above.

Setting Line Type The type of each ﬂuidic line can be changed from the standard line type,

“Main Line”, to the special line type “Control Line”. Being in Edit Mode,

double clicking on a ﬂuidic line or selecting the line and choosing the

menu entry Edit Properties... brings up a dialog box in which you can set

the line type. A control line is shown dashed. Note that—aside from

a different appearance—changing line type has no impact respecting

simulation.

Setting Blind Plugs Before starting a simulation, FluidSIM checks for open connections and,

on request, will ﬁt a blind plug. You can set or delete such blind plugs in

the Edit Mode by double clicking on the desired hydraulic connection.

A dialog box appears, in which you can either set or remove a blind

plug for the selected connection. Another way to go about changing

blind plugs is to select the desired connection and then click under Edit

Properties... , which will open the desired dialog box.

4. Advanced Concepts in Simulating and Creating Circuits

Hydraulic connections that are ﬁtted with a blind plug are indicated

clearly with a crossbar.

Zoom Features The content of windows can be enlarged by clicking on or View

Zoom In or reduced by using or View Zoom Out .Theshortcutkeys

for this function are >and <respectively. If your mouse device is

equipped with a mouse wheel you can roll the wheel while holding down

the Ctrl key to zoom in.and out, respectively

If you click on or View Zoom by Rubber Band and then draw a rectangle

with the rubber band, the selected area will be shown enlarged. You

can also switch between the current and previous view of a window by

clicking on or View Previous View .

or View Fit to Window ﬁts the entire circuit to the window; or

View Standard Size shows the circuit diagram without enlargement or

reduction.

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4. Advanced Concepts in Simulating and Creating Circuits

Background Grid By clicking on , the background grid is shown. By clicking under

Options Grid... , a dialog box appears that allows you to select between

grid types and line resolution.

Description of the dialog box:

•“Width”

The grid width deﬁnes how close together the lines of the grid

should be. You can choose between “Coarse”, “Medium”, or “Fine”.

•“Style”

There are three types of grid to choose from “Point”, “Cross”, or

“Line”.

•“DisplayGrid”

This selection displays or hides the background grid.

Grouping Objects If objects shall be subsumed under a single group, select them and

click Edit Group . Groups can be nested. The objects of a group can

be selected, moved, deleted, or copied only all at once. However,

component properties can be edited individually, as usual, by either

double clicking the object or choosing the respective entry in the

component’s context menu.

4. Advanced Concepts in Simulating and Creating Circuits

Ungrouping Objects To ungroup a collection of objects, click Edit Ungroup . Note that only the

outermost group is resolved; repeated ungrouping will resolve nested

groups.

4.2

Additional Simulation

Functions

This section describes in detail additional functions that apply to the

simulation of circuit diagrams.

Simultaneous Actuation of

Several Components

During the Simulation Mode, it is sometimes necessary to actuate

more switches or valves simultaneously. It is possible in FluidSIM to

simulate just such an actuation by means of setting a component in a

permanently actuated state. A button (or a manually operated valve) will

become permanently actuated when clicking on it while holding down

the Shift key. This permanent actuation will be released by a simple

click on the component.

Switching to the Edit Mode If a component is dragged from the component library to the circuit in

the drawing area, and the simulation has been paused , FluidSIM

automatically switches to the Edit Mode.

Editing and Simulating in

Parallel

In FluidSIM it is possible to open more than one circuit diagram at a

time. Each circuit can either be simulated or edited. This fact means

that the Simulation Mode and the Edit Mode are applied uniquely and

independently to each window containing a circuit diagram.

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4. Advanced Concepts in Simulating and Creating Circuits

This concept means that it is possible to edit one circuit diagram, while

other circuits are in the background running in simulation:

It’s in the nature of hydraulics that the simulation of circuits is a

demanding problem. Therefore, when using a lower-performance

computer, the editing of new circuit diagrams often appears jerky

when simulations of other circuits are simultaneously running in the

background. So that working in the Edit Mode goes more smoothly, all

simulations performed in the background should be stopped.

4. Advanced Concepts in Simulating and Creating Circuits

4.3

Linking Components

Automatically

In order to make circuit design efﬁcient, FluidSIM provides more

functions to facilitate component linking.

Insertion of T-connections FluidSIM automatically inserts a T-connection when a line is drawn from

a component

connection

. to an already existing line. This functionality

applies to hydraulic as well as electrical lines.

4.4

Current Path Numbering

and Switching Elements

Table

The automatic generation of current paths simpliﬁes the identiﬁcation of

switches and relays when constructing electrical circuits. Along with

the generated switching element tables FluidSIM makes it easy to

understand which switches are controlled by which relays. To make

the automatic labeling feature a satisfactorily working concept, the

following points should be obeyed.

• The +24V current path should form the top horizontal line.

• The 0V current path should form the bottom horizontal line.

• The electric make/break/changeover switches should be placed

above the relays.

• The relays should be placed closed to the bottom 0V current path.

• All connections of a vertical current path should align.

• The horizontal distances between the paths should be equal and of

reasonable distance.

If the automatic numbering or the label positions are not entirely

satisfying, a manual adjustment of a few lines or components will yield

the desired layout quality in most cases. If two separated electrical

circuits cause an unfavorable numbering, try to increase the distance

between these circuits.

The automatic current path numbering can enabled or disabled via View

/Display current path numbering and switching elements table .

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4. Advanced Concepts in Simulating and Creating Circuits

4.5

Displaying Quantity

Values

The values for all or only selected quantities of a circuit can also be

displayed without measuring instruments.

> Click under the View menu on Quantity Values... to open the dialog

box for the display of quantities:

For each of the listed quantities (“Velocity”, “Pressure”, ...) a display

mode can be chosen.

When displaying pressure values it can be chosen between two different

units, “Bar” and “MPa”. This setting affects the display of pressure

values at connections, at components, and within state diagrams.

4. Advanced Concepts in Simulating and Creating Circuits

Description of the dialog box:

•“None”

No values are displayed for this quantity.

•“Particular”

Values are displayed at those connections that the user has

previously chosen.

• “All”

Values are displayed at all connections for this quantity.

• “Display Measurement Units”

Enable this option if both state values and the related units shall be

displayed.

For each quantity there is a key short cut for toggling between the three

display modes. The “Shortcut” column of the dialog box for the quantity

displayshowstheappropriatekeys.

Selecting connections for the display of single parameters is explained

here:

>Openacircuitdiagram.

> Change into the Edit Mode and double click on a component

connection, or click under the Edit menu on Properties... .

A dialog box with the connection settings opens. The ﬁeld “Show

Values” deﬁnes the state values to be displayed when the “selected”-

option in the state values dialog box is chosen. However, if the “no”-

option in the state values dialog box is chosen, even the checked state

values are not displayed.

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4. Advanced Concepts in Simulating and Creating Circuits

The settings for the display behavior for state values belong to

the current circuit diagram only. Hence, for several open circuit

diagrams, different view options can be deﬁned. By clicking on Options

Save Settings Now , the view option settings of the current circuit are saved

and serve as default for newly opened circuit diagrams.

Special Features of the

Quantity Display

Vector quantities are characterized by an absolute value along with a

direction. To indicate the direction within a circuit diagram the signs “+”

(into or toward a component) and “–” (out of or away from a component)

are used. An arrow may also be used to display direction. FluidSIM uses

both representations:

Quantity Direction indicator

Flow Sign, arrow

Velocity Sign

Force Sign

Current Sign

The arrow as a direction of ﬂow indicator can be turned on or off by

clicking under View Display Flow Direction . The arrow for the direction of

ﬂow will be shown clear the component connection, that is, as long as

the ﬂow is other than zero.

If the total value of a quantity is extremely near to zero (< 0.0001), no

numerical value will be displayed. Rather, the symbol “> 0” for a small

positive value or “< 0” for a small negative value is shown.

4. Advanced Concepts in Simulating and Creating Circuits

4.6

Displaying State

Diagrams

The state diagram records the state quantities of important components

and depicts them graphically.

Note that several state diagrams can be used in the same circuit;

however, several components may also share the same state diagram.

A component is added by simply dropping it onto the state diagram. If a

component is dropped a second time on the diagram, it will be removed

from there.

> Being in Edit Mode click on Edit Properties... .

The following dialog box opens:

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4. Advanced Concepts in Simulating and Creating Circuits

Description of the dialog box:

• “Display Interval”

Deﬁnes start and end point in time for state value recording. These

boundaries must not be known prior to a simulation but can be set

afterwards since FluidSIM records always all state values during the

entire simulation period.

If the “Adjust automatically”-option is enabled, boundaries of the

time interval are ignored. The timeline is scaled such that the entire

simulation time is always displayed.

• “Log File”

The state values be written to a ﬁle. To enable this option enter the

complete path of a ﬁle and set a reasonable step width.

Note that a large amount of data can be written the step width is

very small. Hence, if necessary, shorten the simulation interval or

increase the step width.

If the option “Record state changes only” is enabled, FluidSIM lists

only values if at least one state variable incurred a state change.

This option simpliﬁes the detection of interesting simulation points-

•“Color”

Deﬁnes the color of the diagram. It is set by clicking on the down-

arrow at the right-hand side of the list and selecting a color.

• “Fill Area”

Deﬁnes whether the entire diagram or only its frame is ﬁlled with

speciﬁed the color.

•“Layer”

Sets the drawing layer of the diagram. It is set by clicking on the

down-arrow at the right-hand side of the list and selecting a layer.

Depending on drawing layer the diagram may be invisible or not

selectable. In such a case the drawing layer must be activated via

View Layers... before the diagram can be modiﬁed.

4. Advanced Concepts in Simulating and Creating Circuits

State quantities of the following components can be recorded and

displayed in the state diagram:

Component State

Cylinder Position

Way valve Position

Manometer Pressure

Flow meter Flow

Pressure or switching valve State

Switch State

4.7

Superﬁcial Circuit

Checking

Before a simulation is started, the circuit diagram can be checked to see

if there are any

graphic

drawing mistakes present. The mistakes that

lead to errors include the following:

1. objects outside of the drawing area

2. lines that cross through components

3. superimposed lines

4. superimposed components

5. superimposed connections or connections that do not go together

6. open hydraulic connections

7. components that have the same identiﬁcation assigned

8. mismatched labels (see section 4.8)

9. lines that cross through connections to which they are not

connected

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4. Advanced Concepts in Simulating and Creating Circuits

The following circuit diagram contains mistakes of type 2, 3, 4, and 6:

> Click on or Execute Check Superﬁcially .

Message boxes should now appear, which inform the user of the graphic

mistakes.

4. Advanced Concepts in Simulating and Creating Circuits

After the instructions, you may decide if the circuit should be simulated

anyway:

In the case that you start a circuit with open hydraulic connections Fluid-

SIM automatically closes these connection with blind plugs.

4.8

Coupling Hydraulics,

Electrics and Mechanics

In the same way FluidSIM allows you to create hydraulic circuit

diagrams, the software also allows you to design electrical circuits. The

components for the electrical circuits can be found in the component

library and dragged from there to be inserted on the drawing area.

Electrical components are connected in the same way that ﬂuidic

components are.

66 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

4. Advanced Concepts in Simulating and Creating Circuits

The following illustration shows a small example:

> Create this circuit diagram on your computer.

> Start the simulation and observe that the indicator light is

illuminated.

There are also electrical components that link electrical circuits with

hydraulic circuits. These linking components include switches that are

hydraulically operated and solenoids that control directional valves.

Electrical circuits are drawn independently of hydraulic circuits.

Therefore, there needs to be a way to create deﬁnite links between

electrical components (such as a control solenoid) and hydraulic

components (such as a directional valve). So-called

labels

bridge the

difference and link both circuit diagrams together.

4. Advanced Concepts in Simulating and Creating Circuits

A label has a speciﬁc name and can be assigned to a component. If

two components have the same label name they are linked together,

although no apparent line is visible between them.

Entering a label takes place in a dialog box, which can be opened

by either double clicking on the desired component or selecting the

component and then clicking Edit Properties... . Labels can be established

on the left and right sides of an electrically operated valve by double

clicking on the appropriate side, as opposed to clicking in the middle of

the component.

The following example explains how labels can be used in FluidSIM.

> Activate the Edit Mode by clicking on or Execute Stop .

> Create the circuit diagram as shown in the following ﬁgure:

68 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

4. Advanced Concepts in Simulating and Creating Circuits

So that the valve can be controlled by the solenoid, you have to link the

components with a label.

> Double click on the control solenoid or simply select the control

solenoid and click under Edit Properties... .

The following dialog box appears:

Description of the dialog box:

•“Label”

This text ﬁeld gives the label its name. A label can be up to 32

characters in length consisting of letters, numbers, and symbols.

> Enter a name for this label, for example “Y1”.

> Double click on the outside of the valve solenoid to open the dialog

box for the label name.

> Input the same label name as for the solenoid, for example “Y1”.

The solenoid is now linked to the valve.

In practice the valve solenoid would not be directly controlled by the

switch, rather via an intermediate relay. This component has been

neglected here for the sake of simplicity.

> Start the simulation.

4. Advanced Concepts in Simulating and Creating Circuits

The electrical current as well as the pressure and ﬂow distribution are

computed; the pressures are shown in color.

If you want to see the exact values of the quantities at hand, you

can mark them by clicking under View Quantity Values... .Themarked

quantities are displayed next to the components’ connections. Section

4.5 applies here.

> Operate the electrical switch.

As a result the valve switches and the cylinder’s piston extends:

Electrically or hydraulically operated valves can only be switched

manually, when there is no control signal applied.

70 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

4. Advanced Concepts in Simulating and Creating Circuits

Aside from a manual or electrical operation, valves can be controlled

mechanically

, either through a cylinder piston or a magnet mounted

at the piston. Such a coupling is realized in the same way an electrical

coupling is established: By means of labels, which are assigned to the

cylinder’s distance rule and the mechanical valve connection.

> Draw a conﬁgurable valve on the drawing area and furnish it with a

mechanical actuator.

> Double click the mechanical actuator.

A dialog opens where a string for the related label can be entered. If

the same label is assigned to the cylinder’s distance rule, the valve

will become actuated mechanically if the cylinder piston reaches its

predeﬁned position.

Display Styles for Labels If a label shall be displayed framed, similar to the display of component

descriptions, click onto View Labels... .

The following dialog box opens:

4. Advanced Concepts in Simulating and Creating Circuits

In the dialog box for each label of the circuit its style, framed or not

framed, can be deﬁned.

4.9

Operating Switches

This section describes how to operate switches by means of cylinders,

relays, pressure, or other switches.

Switches at Cylinders Limit switches, proximity switches, and mechanically operated valves

can be activated by the piston of the cylinder. Therefore, it is necessary

to use a distance rule at the cylinder to position the switches correctly:

> Drag a cylinder and a distance rule to the drawing area.

> Drag the distance rule near to the cylinder.

When the distance rule is dropped near the cylinder, it automatically

snaps in the right position. Move the cylinder just slightly and the

distance rule moves with it. If you move the cylinder more than a

centimeter in distance, the connection between distance rule and

cylinder is broken, and the distance rule does not travel with.

The correct position for a distance rule depends on the type of cylinder.

Distance rules can be set

above

the cylinder,

before

the cylinder (on the

moving piston), or at both positions at the same time:

> Double click on the distance rule.

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4. Advanced Concepts in Simulating and Creating Circuits

The following dialog box appears:

Description of the dialog box:

•“Label”

The text insertion ﬁelds on the left are for naming labels from

proximity switches or limit switches in electrical circuits, which

are actuated by the movement of the cylinder’s piston.

•“Position”

The text insertion ﬁelds on the right are for deﬁning the exact

position of the switches on the cylinder.

> Insert “Y1” as the label name in the ﬁrst row and “35” for its

position. Close the dialog box by clicking on “OK”.

4. Advanced Concepts in Simulating and Creating Circuits

Immediately following, a mark with the appropriate label appears

beneath the distance rule:

As a consequence, the cylinder will activate the switch or the valve

labeled “Y1” if its piston has traveled by 35 mm. To deﬁne a label in the

electrical circuit double click on the respective component; to deﬁne

a label at a mechanical actuator of a valve double click the respective

“connection” of the valve.

Relays By using relays, more than one switch can be actuated simultaneously.

It is therefore necessary to couple the relay with the appropriate

switches. Thus in FluidSIM also relays possess labels, which can be

used to couple relays and switches in the previously described way. By

double clicking on a relay, the dialog box for a label name appears.

The following illustration shows an electrical circuit in which a relay

operates two break switches and two make switches at the same time:

Besides simple relays, relays with switch-on delay, relays with switch-off

delay, and relay counter exist. These relays are used when the linked

switch should be actuated after a preset time interval or a number

of pulses received. By double clicking on these relays, a dialog box

appears where the appropriate values can be entered.

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4. Advanced Concepts in Simulating and Creating Circuits

Coupling Mechanical

Switches

To mechanically couple mechanical (manually operated) switches in Flu-

idSIM, you have to use labels. When more than one mechanical switch

has the same label, all these switches operate with the switching of only

one.

Automatic Switch Altering FluidSIM recognizes delay switches, limit switches, and pressure

switches by the nature of their usage and by their labels and supplies

the corresponding symbol for the switch in the electrical circuit: for

switch-on delayed,for switch-off delayed,for mechanical operated

switches, and for pressure operated switches. The representation of

switches that are actuated by cylinders can be determined by selecting

the corresponding switch type in the component’s properties dialog:

This means that there do not exist special symbols for these switches in

the FluidSIM component library. Instead the symbols for simple switches

can be utilized:

4. Advanced Concepts in Simulating and Creating Circuits

4.10

Adjustable Components

Certain components contain parameters that can be set in the Edit

Mode. A number of these components have been discussed in earlier

sections. The following table gives a complete overview:

Component Adjustable parameter

Check valve Opening pressure

Counterbalancing valve Nominal pressure

Cylinder Name, force, max. stroke, piston

position, piston area, piston ring area

Diaphragm type accumulator Gas pre-charge pressure,

nominal pressure at ﬂow

Flow control valve Nominal ﬂow

Hose Length

Pressure reducing valve Nominal pressure

Pressure relief valve Nominal pressure at ﬂow

Pressure switch Switching pressure

Pump unit Operating pressure, ﬂow

Delay relay Delay time

Relays counter Counting pulses

Shut-off valve Opening level

One-way ﬂow control valve Opening level

Throttle valve Opening level

The dialog box for setting these parameters can be opened with a

double click or Edit Properties... .

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4. Advanced Concepts in Simulating and Creating Circuits

4.11

Settings for Simulation

By clicking Simulation... or Sound... under the Options menu, parameters

and options can be set for simulation.

Simulation Parameters By clicking under Options Simulation... a dialog box appears with

parameters for simulation:

Description of the dialog box:

•“LineColors”

During simulation the electrical, the hydraulic and the digital lines

get colored, depending on their state. The mapping from a state to

a color is set by clicking on the down-arrow at the right-hand side of

the list and selecting a color.

4. Advanced Concepts in Simulating and Creating Circuits

•“Slow-motionFactor”

The slow-motion factor controls whether the simulation should go

more slowly then it would in reality. With a slow-motion factor of

1:1, the simulation should proceed in real-time.

•“PistonMovement”

With the setting “Keep Real-time” FluidSIM animates the piston

as it would move in reality (real-time). The slow-motion factor is

still considered. The requirement for the observance of real-time

requires a powerful computer.

The setting “Smooth” uses the available power of a computer to

its best advantage. The goal here is to run the simulation without a

sticky piston movement. Hence the movement of the piston can be

faster or slower than the piston movement in reality.

•“Labeldesignation”

By default, FluidSIM does not distinguish between uppercase

and lowercase characters in label identiﬁers of mechanical or

electrical connections. I. e., label identiﬁers are automatically

converted to uppercase. Now, using the option “Display uppercase

and lowercase”, label identiﬁers are treated case sensitively.

Case sensitivity can be enabled for both display purposes and a

more strict label identity checking. In the former case, upper- and

lowercase characters, say, for instance “a” and “A”, are displayed as

such, but treated as the same character. In the latter case, which

is enabled by the option “Distinguish between uppercase and

lowercase”, “a” and “A” are treated as different labels.

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4. Advanced Concepts in Simulating and Creating Circuits

• “Digital Technique (Compatibility with Siemens LOGO!Soft)”

It is a useful convention in the ﬁeld of digital technology setting

open input ports of AND, NAND, and NOT components to "Hi".

Otherwise, e. g. an AND gate with three input ports would

not function as expected if only two of its input ports were

connected. Many

constant

"Hi" connections may clutter up a circuit

unnecessarily, and hence FluidSIM can be conﬁgured to set open

input ports of the respective components always to "Hi". This

option can be disabled of course. If open input ports have been

detected at the start of the simulation, FluidSIM issues a warning

message. The display of this message can also be disabled.

Sound Parameters By clicking under Options Sound... a dialog box appears with parameters

for sound settings:

Description of the dialog box:

•“EnableSound”

An acoustic signal can be activated or deactivated for each of the

following four component types: switch, relay, valve, and buzzer.

If there is no sound hardware, the settings can be set but not applied.

4. Advanced Concepts in Simulating and Creating Circuits

4.12

OPC and DDE

communication with Other

Applications

FluidSIM can exchange data with other applications; thus it may coupled

with programmable logic controllers, SPS, for instance. Prerequisite

for such a coupling is the ability of the partner application to provide

an “OPC interface” and to act as a so-called “DDE client”, respectively.

From within a FluidSIM circuit the DDE coupling is realized by means of

two electrical DDE components, each of which providing eight inputs

and outputs respectively.

Further information and examples regarding the DDE communication

can be found on the FluidSIM-CD in the DDE directory.

> Firstly, enable the option “Use OPC” in the Options

OPC/DDE Connection... .

> Drag an input (or output) component from the component library

and open the property dialog box by double clicking the component

or by clicking on Edit Properties... .

The following dialog box opens:

Description of the dialog box:

•“OPCServer”

Enter the OPC server here or click on Select ... and select a server

from the list.

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4. Advanced Concepts in Simulating and Creating Circuits

•“Item”

Enter the data item here or click on Select ... and select an item from

the list.

•“ReverseFunction”

Inverts the logical values of the DDE components. Normally, current

ﬂow corresponds to a logical 1.

> Select the option “Use DDE” by clicking Options

OPC/DDE Connection... .

> Select a DDE component from the library, place it onto the drawing

area, and open its property dialog box by either double clicking or

via Edit Properties... .

The following dialog box opens:

4. Advanced Concepts in Simulating and Creating Circuits

Description of the dialog box:

•“Label”

Label of the DDE component. This label is used from within the

partner application to request or to set values in FluidSIM via DDE.

• “FPC Address”

If FluidSIM is coupled with an application that also provides FPC

addressing support, the addresses of assembly, word, and byte can

be entered here. These settings are necessary only if the option

FPC mode is active.

•“ReverseFunction”

Inverts the logical values of the DDE components. Normally, current

ﬂow corresponds to a logical 1.

4.13

Settings for the OPC/DDE

communication

Clicking on Options OPC/DDE Connection... opens the following dialog box

with settings for the OPC and DDE communication:

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4. Advanced Concepts in Simulating and Creating Circuits

Description of the dialog box:

• “Do not apply remote control”

This option disables OPC and DDE communication in FluidSIM. If

this option is checked FluidSIM will not respond on attempts to

open a connection by other applications.

•“OPCmode”

Choose this option, if FluidSIM shall be coupled with other

applications via OPC.

• “Buffer events”

Enable this ﬁeld, if FluidSIM shall buffer all events and process

them in a ﬁrst-in-ﬁrst-out manner. If this option is disabled, events

that occur during high computational load may go lost.

• “DDE mode”

Choose this option, if FluidSIM shall be coupled with other

applications via DDE.

•“Server”

Deﬁnes the name under which name FluidSIM logs on the partner

application. As the case may be, this name must be told the partner

application as the

server

name.

•“Topic”

A topic is necessary to agree upon a common label for the data

exchange. As the case may be, the topic must be told the partner

application.

• “FPC Addressing Mode”

This option must be checked if FluidSIM is coupled with an

application that also provides FPC addressing support.

TheusageoftheOPC/DDEinterfaceisintroducedinChapter4.12.

5. Learning, Teaching, and Visualizing Hydraulics

Beside the creation and simulation of electro-hydraulic circuit diagrams,

FluidSIM also supports teaching basic hydraulic knowledge. This

knowledge is presented in the form of texts, overview pictures, sectional

views, exercises, and educational ﬁlms. Functions that realize the

selection of this instruction material are found under the Didactics menu.

One group of these functions refers to information about single,

selected components. Another group of functions refers to ordered

overviews of the didactics material, allowing the selection of an

interesting topic. Finally, it is also possible to select and link together

arbitrary topics into so-called “presentations”.

Appendix B, “The Component Library”, and C, “Didactics Material

Survey”, offer a complete and concise summary of the instructional

material in FluidSIM.

The following sections contain a description of the functions found

under the Didactics menu.

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5. Learning, Teaching, and Visualizing Hydraulics

5.1

Information about Single

Components

The ﬁrst three entries under the Didactics menu refer to selected

components and are context sensitive. More precisely:

When a component in the current circuit diagram window is selected,

or all selected components are of the same type, the menu entry

Component Description will be enabled.

In the case that a photo or a further illustration exists relative the

selected components, the following functions can also be utilized:

Component Photo and Component Illustration . In the case that varying types

of components have been selected, the choice of components is not

clear, and none of the above three menu entries will be enabled.

If the current window shows a picture from the didactics material, the

menu entry Topic Description will be enabled.

Component Descriptions All components possess a page with a technical description. This page

contains the diagram symbol for the component according to the DIN

standard (“Deutsche Industrienorm”), a textual description of the

component’s function, the designations of the connections, and a listing

of the adjustable parameters along with their value ranges.

> Select the one-way ﬂow control valve, and click on the menu item

Component Description under the Didactics menu.

5. Learning, Teaching, and Visualizing Hydraulics

The following page opens:

Under the heading “Related Topics”, but also when appropriate in

the component description, cross references for related instruction

material and components are deﬁned. By clicking on a cross reference,

the related page will automatically be displayed.

Component Photos In FluidSIM most components possess an accompanying photo.

> Select for example a cylinder and click on Component Photo in the

Didactics menu.

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5. Learning, Teaching, and Visualizing Hydraulics

The following photo appears on the screen:

In the case that a component cannot exist singularly in a real system,

FluidSIM displays a photo of the assembly group that this component

belongs to. Examples for such components include the indicator light,

relays, switches, and the electrical power supply.

Components, that do not exist in reality, simply have no photo.

Examples include the text component and the distance rule.

Component Illustrations Component illustrations provide useful information relating a compo-

nent’s function. This may include a sectional view of the component,

but also illustrations of the component’s usage within a circuit diagram.

For several components, their sectional view can be animated like a

cartoon.

> Select a 4/2-way hand-lever valve and click on Component Illustration

under the Didactics menu.

5. Learning, Teaching, and Visualizing Hydraulics

The following dialog box appears:

Description of the dialog box:

•“Topics”

This ﬁeld contains a listing of sectional views, animations, and

circuits which refer to the functional characteristics of a single

component. By double clicking on a line in the list, the dialog box

disappears, and a window with the selected information is opened.

The highlighted bar in the topics list can be moved by mouse click

or by using the arrow keys; however, the highlighted bar will not

respond to any movement of the scrollbars.

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5. Learning, Teaching, and Visualizing Hydraulics

•“Preview”

When the “Preview” setting is activated, the picture that pertains to

a selected topic appears underneath the topics list.

> Click on the line for topic [74.1] 4/

2-way valve, three pistons (1) .

The following picture appears:

Often it is easier to understand the functional nature of a component,

when its behavior is visualized through the use of animation. For

this reason, several components possess different sectional views

showing the component at different states. These sectional views can be

animated in much the same way as a ﬂip book.

> Select a 3-way pressure reducing valve, and click on

Component Illustration in the Didactics menu.

5. Learning, Teaching, and Visualizing Hydraulics

> Double click on a topic referring a sectional view that can be

animated.

> Click on or Execute Start to start the animation.

An animation can be “frozen” with or by clicking on Pause in the

Execute menu. or Execute Stop stops an animation, whereas or

Execute Reset restarts an animation.

In addition, there is a loop mode for animation. When this mode is

turned on, an animation will run and repeat itself until is clicked. The

loop mode can be activated in the dialog box for the didactics options,

which is opened by clicking on Didactics... Options .

When more than one topic pertains to a component, or there exist

additional topics to similar components, a dialog box containing a listing

of these topics is opened when clicking on Component Illustration .

Topic Descriptions FluidSIM also provides a textual description for all topics in the didactics

material. If the current window contains a picture from the didactics

material, for example a sectional view of a component or an exercise,

a page with the related topic description can be opened by clicking on

Didactics Topic Description .

> Open the topic 32by clicking on Working Principle... in the Didactics

menu.

> Click on Topic Description in the Didactics menu.

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5. Learning, Teaching, and Visualizing Hydraulics

The following page opens:

Beneath the textual description, also a miniaturized representation of

the related picture is given.

5.2

Selecting Didactics

Material from a List

The entries Hydraulics Basics... ,Working Principle... ,and Exercise... under

the Didactics menu present the didactics material of FluidSIM organized

in the form of three topics lists. From these lists topics can be chosen

and viewed independently of the current window and possibly selected

components.

Hydraulics Basics Under this menu entry those overview pictures, sectional views,

and animations are comprised that aid in teaching basic hydraulic

knowledge. Here you can ﬁnd information for such topics as the

representation of diagram symbols and their meaning, animations

relating to element designations, and simple circuit diagrams that

demonstrate the interaction of individual components.

5. Learning, Teaching, and Visualizing Hydraulics

> Click on Hydraulics Basics... under the Didactics menu to open a dialog

box containing the topics list for basic concepts in hydraulics.

Description of the dialog box:

•“Topics”

This ﬁeld contains a listing of topics pertaining to basic hydraulic

knowledge. By double clicking on a line in the list, the dialog box

disappears, and a window with the selected information is opened.

The highlighted bar in the topics list can be moved by mouse click

or by using the arrow keys; however, the highlighted bar will not

respond to any movement of the scrollbars.

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5. Learning, Teaching, and Visualizing Hydraulics

•“Preview”

When the “Preview” setting is activated, the picture that pertains to

the selected topic appears underneath the topics list.

Clicking on “OK” has the same function as double clicking on a line

in the topics list; clicking on “Cancel” closes the dialog box without

choosing a topic.

If the chosen topic is an animation, it can be started by clicking on

(see section 5.1).

5. Learning, Teaching, and Visualizing Hydraulics

Working Principles Sectional views that refer to the function of single components can

be found under Working Principle... in the Didactics menu. For several

components, their sectional view can be animated. In the same way that

a topics list is opened for the hydraulics basics, a dialog box containing

a list of topics is opened when clicking on Didactics Working Principle... .

Description of the dialog box:

•“Topics”

This ﬁeld contains a listing of sectional views that refer to the

function of single components. By double clicking on a line in the

list, the dialog box disappears, and a window with the selected

information is opened. The highlighted bar in the topics list can

bemovedbymouseclickorbyusingthearrowkeys;however,the

highlighted bar will not respond to any movement of the scrollbars.

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5. Learning, Teaching, and Visualizing Hydraulics

•“Preview”

When the “Preview” setting is activated, the picture that pertains to

the selected topic appears underneath the topics list.

Exercises FluidSIM provides 11practice assignments with standard exercises

in the ﬁeld of electro-hydraulics. Each assignment consists of three

pictures. The ﬁrst picture shows the problem, and the second picture

shows one attempt at solving to demonstrate a basic idea. The third

picture shows the complete solution in the form of a circuit diagram.

5. Learning, Teaching, and Visualizing Hydraulics

> Click on Didactics Exercise... to open a dialog box that contains the

exercises.

Description of the dialog box:

•“Topics”

This ﬁeld contains a listing of exercises, which are always based on

three pictures. By double clicking on a line in the list, the dialog box

disappears, and a window with the selected information is opened.

The highlighted bar in the topics list can be moved by mouse click

or by using the arrow keys; however, the highlighted bar will not

respond to any movement of the scrollbars.

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5. Learning, Teaching, and Visualizing Hydraulics

•“Preview”

When the “Preview” setting is activated, the picture that pertains to

the selected topic appears underneath the topics list.

> By double clicking on its name in the dialog box, choose the

exercise Roller conveyor (flow resistance) .

The following window is opened:

To go on to the next picture, you must either click on or set the

exercise to an automatic continuation (see section 5.6).

5. Learning, Teaching, and Visualizing Hydraulics

5.3

Presentations: Combining

Instructional Material

Sometimes you may want to examine a topic from different angles or

combine individual topics into a lesson. For this purpose FluidSIM offers

the concept entitled “presentation”.

There are a number of already prepared presentations, which can be

found on the FluidSIM installation disks. However, editing presentations

or creating new presentations is also possible with FluidSIM. All

presentations can be found under Presentation... in the Didactics menu.

> Click on Didactics Presentation... .

The following dialog box appears:

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5. Learning, Teaching, and Visualizing Hydraulics

Description of the dialog box:

• “Available Presentations”

This ﬁeld contains a list of already created presentations.

• “New Presentation...”

Clicking on “New Presentation...” opens a second dialog box for the

creation of a new presentation.

• “Edit Presentation...”

Clicking on “Edit Presentation...” opens a second dialog box to

begin editing a presentation.

•“Preview”

When the “Preview” setting is activated, the picture that pertains to

the selected presentation appears underneath the topics list.

5. Learning, Teaching, and Visualizing Hydraulics

> Click on “New Presentation” to open the following dialog box.

Description of the dialog box:

•“Description”

In this text ﬁeld a short description of the presentation can be

entered. This text may consist of up to 128 characters and will

appear with the other presentations, the next time the presentation

dialog box is opened.

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5. Learning, Teaching, and Visualizing Hydraulics

• “Available Topics”

This ﬁeld contains a list of all available topics dealing with

“Hydraulic Basics”, “Working Principles”, and “Exercises”.

Moreover, there exist two pictures that can be used to announce

a refreshment and a lunch break respectively. A double click on a

line in the “Available Topics” list inserts this line in the “Selected

Topics” list above the highlighted bar. In this way a presentation

can be created or altered.

Moreover, a user can integrate his own circuit diagrams, DXF ﬁles,

BMP- and WMF-picture ﬁles, or even multimedia ﬁles such as

sounds or video clips. To do so, click on “User File...”: A dialog

box opens that allows for the selection of the desired data source

on the ﬁle system.

• “Selected Topics”

This ﬁeld contains a list of topics chosen for the current

presentation.

•“Insert”

Clicking on “Insert” is the same as double clicking a line in the

“Available Topics” list: The selected line in “Available Topics” will be

inserted in the “Selected Topics” list.

•“Delete”

Clicking on “Delete” deletes the selected line of the “Selected

Topics” list.

•“Preview”

When the “Preview” setting is activated, the picture that pertains to

the selected topic appears underneath the respective list.

Within both topics lists the highlighted bar can be moved using the

arrow keys. Maybe it will be necessary to click and select the list you

want to work with.

5. Learning, Teaching, and Visualizing Hydraulics

After creating a new presentation and closing the dialog box by clicking

on “OK”, FluidSIM asks you to name the presentation

ﬁle

.Presentation

ﬁles have the extension .shw and are located in the subdirectory shw

under the fl_sim_h directory.

The structure of a presentation ﬁle is described more thoroughly in

section 7.2.

5.4

Extended Presentations in

the Microsoft PowerPoint

Format

FluidSIM 3 contains an additional large set of presentations written

in the Microsoft PowerPoint Format. To use these presentations,

PowerPoint must not be installed on your PC since FluidSIM installs

the necessary viewer at its installation time.

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5. Learning, Teaching, and Visualizing Hydraulics

> Click on Extended Presentation... to open the dialog box of a

presentation.

> Select the item “Actuators” to open the related presentation in full

screen mode.

Most of the topics form a picture sequence, which can be viewed in a

single-step manner using the left mouse button or the spacebar.

5. Learning, Teaching, and Visualizing Hydraulics

> Move two single steps forward in the current presentation.

When clicking the right mouse button, a context menu is opened by

which, among others, the presentation can be closed or particular

pictures picked out.

The ﬁles of the extended presentations are in the subdirectory ppx of

the FluidSIM installation. You can add new PowerPoint presentations on

your own by copying the related ﬁles (format: “ppt” or “pps”) into the

ppx-directory.

Like the other didactics material (illustrations of function, component

photos, circuit drawings, educational ﬁlms, etc.), the PowerPoint

presentations can linked and used within presentations (cf. Section 5.3).

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5. Learning, Teaching, and Visualizing Hydraulics

5.5

Playback of Educational

Films

The FluidSIM CD-ROM contains 15educational ﬁlms, which last between

1 to 10 minutes in length and cover a speciﬁc area of electro-hydraulics.

> Click on Didactics Educational Film... to open the dialog box that

contains a list of the educational ﬁlms.

Description of the dialog box:

• “Available Educational Films”

This ﬁeld contains a list of available educational ﬁlms.Bydouble

clicking on a line in the list, the dialog box closes and the media

playback starts playing the selected ﬁlm.

5. Learning, Teaching, and Visualizing Hydraulics

•“Preview”

When the “Preview” setting is activated, a typical scene from the

ﬁlm appears underneath the list of titles.

> Click on The Hydraulic Power Unit to start the playback of

the selected ﬁlm:

106 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

5. Learning, Teaching, and Visualizing Hydraulics

Underneath the window for the media playback, you will the ﬁnd the

control elements to start, stop, and wind the ﬁlm. A detailed description

of the media playback is available under the standard Microsoft Win-

dows®help.

5.6

Settings for Didactics

By clicking on Didactics... Options , a dialog box appears that contains the

settings for didactics:

Description of the dialog box:

• “Animation Speed”

This setting deﬁnes the speed at which the animations should run.

• “Spool Presentation”

A presentation in FluidSIM can be set to automatically run. For this

the setting “Automatically after ...Seconds” must be activated. The

time span that can be entered deﬁnes how long FluidSIM waits

before switching to the next topic of the presentation. By clicking

on , the presentation will immediatelychange to the next topic in

the presentation. With the setting set to “Manually”, no automatic

switching will take place during the presentation.

5. Learning, Teaching, and Visualizing Hydraulics

• “Loop”

Deﬁnes whether a running presentation is reset and started over

again after all topics have been displayed. This is known as loop

mode.

If an animation is running unattached to a presentation, for example

when started via Didactics Component Illustration , this setting deﬁnes

as to whether or not the animation will automatically repeat itself.

108 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

This chapter develops further concepts and functions of FluidSIM.

6.1

Drawing Layers

Components in FluidSIM that cannot be simulated, such as texts, DXF

import data, rectangles, circles, state diagrams, and parts lists, can be

assigned to one of eight drawing layers. Each layer can be shown or

hidden as well as set locked or unlocked. These properties are deﬁned

under View Layers... ; here also a layer can be given a name. Components

of FluidSIM that can be simulated are always on layer 1.

•“Description”

The layer name is displayed in the dialog box of an object’s

properties instead of the layer number.

•“Display”

If the option “Show” is disabled, the respective drawing layer is

invisible, and, of course, can not be edited.

6. Special Functions

•“Edit”

If the option “Edit” is disabled, the respective drawing layer is still

visible but cannot be edited. I. e., the objects that belong to such a

locked layer can neither be selected, nor moved or deleted. By this

concept e. g. a drawing frame can be protected. To edit objects on a

locked layer, ﬁrst unlock the layer.

The identiﬁers of components and connections in FluidSIM’s standard

circuit library stand on drawing layer two. By disabling the “Show”-

option for this layer, the identiﬁers are made invisible.

6.2

Graphic Primitives

Rectangles

By selecting a rectangle and clicking on Edit Properties... ,orbysimply

double clicking it, its property dialog box is opened.

Description of the dialog box:

•“x”

Deﬁnes the x-coordinate of the rectangle. Instead of providing a

number, the rectangle can also be moved with the mouse.

•“y”

Deﬁnes the y-coordinate of the rectangle. Instead of providing a

number, the rectangle can also be moved with the mouse.

110 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

•“Width”

Deﬁnes the width of the rectangle. Instead of providing a number,

the rectangle can also be resized by dragging the mouse: If the

mouse pointer is moved onto the rectangle’s border, the mouse

pointers becomes a resize indicator, ,,or .Nowthe

rectangle can be resized as indicated by holding down the left

mouse button.

•“Height”

Deﬁnes the height of the rectangle. Instead of providing a number,

the rectangle can also be resized by dragging the mouse: If the

mouse pointer is moved onto the rectangle’s border, the mouse

pointers becomes a resize indicator, ,,or .Nowthe

rectangle can be resized as indicated by holding down the left

mouse button.

•“Color”

Deﬁnes the color of the rectangle’s border. A color is set by clicking

on the down-arrow at the right-hand side of the list and selecting a

color.

• “Fill Area”

Deﬁnes whether the entire area or only the border of the rectangle

is colored.

•“LineStyle”

Deﬁnes the line style of the rectangle. A line style is set by clicking

on the down-arrow at the right-hand side of the list and selecting a

style.

6. Special Functions

•“Layer”

Deﬁnes the drawing layer of the rectangle. The drawing layer is set

by clicking on the down-arrow at the right-hand side of the list and

selecting a layer.

Depending on the settings of drawing layer, the rectangle may not

be visible or may not be selectable. To display an invisible rectangle

or to change its properties in such a case, the drawing layer must

be activated via the menu View Layers... .

Ellipses By selecting an ellipse and clicking on Edit Properties... ,orbysimply

double clicking it, its property dialog box is opened.

Description of the dialog box:

•“Centerx”

Deﬁnes the x-coordinate of the ellipse center. Instead of providing a

number, the ellipse can also be moved with the mouse.

•“Centery”

Deﬁnes the y-coordinate of the ellipse center. Instead of providing a

number, the ellipse can also be moved with the mouse.

112 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

•“Radiusrx”

Deﬁnes the x-radius of the ellipse. Instead of providing a number,

the ellipse can also be resized by dragging the mouse: If the mouse

pointer is moved onto the ellipse’s border, the mouse pointers

becomes a resize indicator, ,,or . Now the ellipse can be

resized as indicated by holding down the left mouse button.

•“Radiusry”

Deﬁnes the y-radius of the ellipse. Instead of providing a number,

the ellipse can also be resized by dragging the mouse: If the mouse

pointer is moved onto the ellipse’s border, the mouse pointers

becomes a resize indicator, ,,or . Now the ellipse can be

resized as indicated by holding down the left mouse button.

•“StartingAngle”

Deﬁnes the ellipse’s start angle, speciﬁed in degree. A value of zero

degree corresponds to the three o’clock watch hands position.

•“EndingAngle”

Deﬁnes the ellipse’s end angle, speciﬁed in degree. A value of zero

degree corresponds to the three o’clock watch hands position.

•“Color”

Deﬁnes the color of the ellipse’s border. A color is set by clicking

on the down-arrow at the right-hand side of the list and selecting a

color.

• “Fill Area”

Deﬁnes whether the entire area or only the border of the ellipse is

colored.

•“LineStyle”

Deﬁnes the line style of the ellipse. A line style is set by clicking

on the down-arrow at the right-hand side of the list and selecting a

style.

6. Special Functions

•“Layer”

Deﬁnes the drawing layer of the ellipse. The drawing layer is set

by clicking on the down-arrow at the right-hand side of the list and

selecting a layer.

Depending on the settings of drawing layer, the ellipse may not be

visible or may not be selectable. To display an invisible ellipse or

to change its properties in such a case, the drawing layer must be

activated via the menu View Layers... .

6.3

Text Components and

Identiﬁcations

The concept of text components in FluidSIM gives the user a way in

which to describe components in diagrams, assign identiﬁcation texts,

or to provide commentary on the diagram. The text and the appearance

of text components can be customized to the user’s liking.

Text components function in much the same as other ﬂuidic or electrical

components in FluidSIM. The dummy text component

Text

can be found

in the component library, and it can be dragged onto the drawing area.

However, text components contain no connections.

As long as the setting Options Protect Text Components remains switched

off, the text components can be marked, dragged, deleted, and rotated

in the same way that other components are handled. When this setting

is activated, the text components can neither be marked nor moved or

deleted. This concept allows the text components to be anchored in the

background. They are out of the way and cannot interfere with changes

or manipulations made to the circuit diagram while in the Edit Mode.

> Drag the text component from the component library to the drawing

area.

>Makesurethat

Options Protect Text Components is switched off.

114 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

> Double click on the text component or click under Edit Properties...

to open the dialog box for entering new text.

Description of the dialog box:

•“Text”

In this ﬁeld the text to be displayed is entered. A new line is entered

by holding down the Ctrl-key while hitting the Return key.

• “Alignment”

Activates horizontal text alignment.

• “Font...”

By clicking on “Font...”, a Microsoft Windows®common dialog box

opens, which allows you to set the font attributes for the given text.

• “Frame Text”

Draws a border around the text.

6. Special Functions

•“Layer”

Deﬁnes the drawing layer of the text component. The drawing layer

is set by clicking on the down-arrow at the right-hand side of the list

and selecting a layer.

Depending on the settings of drawing layer,thetextcomponent

may not be visible or may not be selectable. To display an invisible

text component or to change its properties in such a case, the

drawing layer must be activated via the menu View Layers... .

The dialog box can be closed by clicking on “OK”. As a result the text

along with its font attributes is inserted into the drawing area.

> Click on Options Protect Text Components to protect the text.

The protected text can no longer be selected. Therefore, components

can be placed over the text.

6.4

Parts Lists

With FluidSIM parts lists can be generated automatically. A parts list

is represented by a “parts list component”, which can be inserted,

moved, or deleted like every other component. The parts list is updated

automatically while a drawing is edited. The automated update may

slow down the drawing process of large circuits and thus, a parts list

component should be inserted in the end of a drawing process.

Inserting a Parts List > Open the circuit demo1.ct.

116 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

> Select the parts list component from either the Insert menu or the

component library and add it to the drawing. Move the parts list

such that it overlaps no other component.

The parts list component analyzes all components of the diagram and

generates table with columns for the component identiﬁcations and

the component designations. In this connection, FluidSIM uses existing

labels and texts as component identiﬁcations.

The sorting of the table can be customized to the user’s liking; moreover,

the parts list can be exported as a text ﬁle. Also note that more than one

parts list component canbeinsertedinadiagram.

6. Special Functions

Properties of Parts Lists > Double-click on a parts list component or select a parts list

component and click on Properties... in the Edit menu.

Description of the dialog box:

•“PartsList”

With the “Accumulated Parts List” option enabled, all components

of the same type become comprised into a single row. As a

consequence, the ﬁrst column of the parts list component shows

the number of the comprised components.

With the “Single Position Parts List” option enabled, each

component gets its own row within the parts list. The ﬁrst column

of the parts list component then shows a possible existing

identiﬁcation.

118 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

•“SortLines”

The lines of a parts list can be sorted in “ascending” order, in

“descending” order, by the “component description”, by the

“component number”, or by the “component designation”.

•“Layer”

Deﬁnes the drawing layer of the parts list component.Thedrawing

layer is set by clicking on the down-arrow at the right-hand side of

the list and selecting a layer.

Depending on the settings of drawing layer, the parts list compo-

nent may not be visible or may not be selectable. To display an

invisible parts list component or to change its properties in such

a case, the drawing layer must be activated via the menu View

Layers... .

Exporting Parts Lists Aside from printing a parts list component, it can also be exported in the

form of a text ﬁle.

> Select a parts list component click on File Parts list Export... .

A ﬁle selector box opens where an existing ﬁle can be selected or a new

ﬁle name can be entered. After a ﬁle has been speciﬁed and the ﬁle

selector box been closed, a dialog box opens where a column separator

can be deﬁned.

•“Tabulator”

The tab-character is used as column separator.

6. Special Functions

•“Semicolon”

The semicolon is used as column separator.

•“Other”

The entered character is used as column separator.

6.5

Printing a Window’s

Contents

FluidSIM contains a practical printing function that is always available,

whether you are in the Edit Mode or the Simulation Mode. The contents

of any window in FluidSIM can be printed.

> Click on File Print... to open the print preview dialog box:

120 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

Description of the dialog box:

•“Printer”

This list contains all available local as well as network printers. A

printer is set by clicking on the down-arrow at the right-hand side of

the list and selecting a printer.

• “Properties...”

Opens a dialog box with available printer options.

•“Copies”

In the number ﬁeld “Number of copies” the desired number of

copies is typed in. If the printout consists of several pages you can

check the “Collate” to have the pages sorted automatically.

• “Scale factor”

In the number ﬁeld “Scale factor” enlargement or reduction of

the circuit diagram is typed in as a percentage. The print preview

window then re-scales the circuit diagram according to the size

proportion that was given.

If the paper size in combination with the chosen scaling factor exceeds

the printer’s printing area, the diagram is printed in a tiled fashion. The

expected number of pages is indicated in the printer preview dialog box.

Pressing the “Fit to paper size” button sets the scale factor so that the

circuit diagram ﬁlls out the entire paper area.

•“Marginadjustment”

In order to take the printable regions of different output devices

into account, or enlarge the margin of a printout, an offset in mm can

be deﬁned for the left as well as the upper margin. Positive values

move the drawing to the right or down, negative values move the

drawing to the left or up.

6. Special Functions

• “Alignment”

In some cases it could be useful to rotate or to mirror the drawing.

E. g. some printer drivers do not support rotating by themselves.

Printing begins by clicking on “OK”.

6.6

DXF Export

FluidSIM contains a ﬁlter module to export circuit diagram in the DXF

format. Hence circuit diagrams from FluidSIM can be imported into a

CAD program, where they can still be edited.

> Click on DXF Export... under the File menu to export the actual circuit

diagram.

If no new name is given for the DXF ﬁle, the exported circuit diagram ﬁle

is saved with the extension .dxf.

The exported drawings in the DXF format differ from those in FluidSIM in

the following manner:

1. Component connections are shown without circles.

2. The DIN symbol is inserted for the cylinder.

3. The text font is set to STANDARD for the text components.

122 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

6.7

DXF Import

Files that are of the DXF format type can be imported, retaining most

of the DXF element attributes. Clearly, imported circuit diagrams or

symbols cannot be simulated since the DXF standard does provide for

a deﬁnition language of physical behavior models. However, the import

functionality is useful if a circuit diagram shall contain elements that

cannot be realized from within FluidSIM. For example, CAD drawing

frames or terminal strip plans, which have been created by means

of another CAD program, can be inserted into a FluidSIM drawing.

Depending on whether a single symbol or a complex drawing is to

be imported, particular conventions relating the grouping should be

obeyed.

Having selected a DXF ﬁle via File Open... , the dialog box for the DXF

import opens.

Description of the dialog box:

•“ScaleDrawing”

The scaling factor deﬁnes scaling in percent that is applied to DXF

ﬁle.

6. Special Functions

• “Each group represents an object”

Enable this option if the DXF ﬁle contains several symbols. Note

that symbol elements that belong together can only be identiﬁed

as such, if they have been grouped within the CAD program in

such a way, that the outermost group of the symbol occurs in the

ENTITIES section. This means among others that no two symbols

can belong to the same group. However, different symbols are

allowed to share blocks; the import ﬁlter of FluidSIM creates copies

for shared blocks.

• “Entire drawing represents a single object”

If this option is enabled, the entire drawing is treated as a single

object.

• “Ignore ungrouped objects”

Enable this option if only for the grouped elements objects shall be

generated. The elements mentioned in section ENTITIES are not

considered.

If this option is disabled, FluidSIM comprises all ungrouped

elements within a single object.

Elements that have been imported can be placed on each of the eight

drawing layers. Moreover, they can be equipped with a designation,

which is displayed in the parts list.

If you have imported a CAD frame, it makes sense to place this frame on

a drawing layer whose “Edit”-option is disabled: This way the frame is

anchored and will not interfere when placing components.

124 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

By double clicking on an imported DXF symbol, the following dialog box

is opened:

Description of the dialog box:

•“Description”

In this ﬁeld a designation can be entered, which is also displayed in

the parts list.

•“Layer”

Deﬁnes the drawing layer of the symbol. The drawing layer is set

by clicking on the down-arrow at the right-hand side of the list and

selecting a layer.

Depending on the settings of drawing layer, the symbol may not be

visible or may not be selectable. To display an invisible symbol or

to change its properties in such a case, the drawing layer must be

activated via the menu View Layers... .

6. Special Functions

6.8

Using and Organizing

Component Libraries

Rearranging a Component

Library

The components in the component library can be rearranged according

to their usefulness and the desire of the user.

> Enlarge the window of the component library.

> Using the rubber band, select for example the following twelve

components:

126 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

> Drag the selected components, for example up and to the right:

6. Special Functions

> It is also possible to rearrange the components in the library

horizontally, in just a few steps:

It is not possible for the user to add components to or delete compo-

nents from the

standard

component libraries. However, own libraries

can be constructed at the user’s will.

128 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

Building New Component

Libraries

In addition to the standard component libraries, which show the Fluid-

SIM-components in

total view

hierarchical view

, or according to the

Flu-

idSIM Version 2

-style, new libraries can be built. A sample component

library has automatically been set up during the FluidSIM installation.

> Choose from the Library menu the library “Frequently Used Way

Valves”.

In contrast to the FluidSIM standard libraries both the arrangement and

the contents of such user-deﬁned libraries can deﬁned, by means of

operations that add and delete components.

6. Special Functions

To display available libraries, to create a new one, or to rename an

existing one, choose the respective entry from the Library menu. The

ﬁrst three entries of this menu belong to the standard libraries. Below,

separated by a line, stand the user-deﬁned libraries.

The bottom entries of the Library menu realize the functions for creating

a new library, New... , for renaming an existing user-deﬁned library,

Rename... , and for deleting a user-deﬁned library, Delete . The latter

two entries relate to active library window.

When clicking on Library New... a dialog box opens, where a description

of the new library can be entered:

The text that has been entered here is shown as a menu entry in the

Library menu. The text can be modiﬁed anytime, by opening the library

and clicking on Library Rename... .

Inserting Components Via

In FluidSIM, several alternative concepts exist to insert a component

into a circuit diagram. One concept is “Drag-and-Drop”, which has been

used in the preceding examples.

Alternatively, components can be selected through the Insert menu,

either by navigating along the hierarchical menu structure or by entering

one or more search strings. While mousing a component description

in the menu, the related symbol is shown either in the preview window

of the search dialog or in the upper left corner of the FluidSIM main

window.

130 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

> Open a new circuit window, select the menu item Insert /

Find Component... and enter one or more search strings; e.g.,

valve, hand.

Description of the dialog box:

•“Words”

In this ﬁeld one or more search items can be entered in order to

ﬁnd a particular component. The order of the search items does not

play a role, they are combined by a logical “AND”. Also note that

partial matches are allowed. I. e., if you are unsure respecting the

correct spelling of a component name, simply partion this name

into several comma-separated search strings.

6. Special Functions

• “Similarity”

Determines the accuracy of the match between “Exact” and

“Fuzzy”. This setting can be used to allow a tolerance respecting

different spelling variants or typing errors.

• “Results”

Contains a list of component descriptions, which contain the

provided search strings. This list is ordered with respect to the

accuracy of the match. By double-clicking onto a line in the list the

dialog box is closed and the related component is inserted in the

circuit diagram. The selection marker in the list can be moved by

simply clicking the mouse, but also by using the arrow keys. Note

that the selection marker does not follow the scroll bars.

•“Preview”

If the “preview” option is enabled, the component symbol of the

selected entry is shown below the list.

Recall that a component can also be searched by navigating along the

hierarchical menu structure.

132 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

> Open a new diagram window and navigate through the menu

hierarchy until you have reached the component “pressure control

valve with manometer”. Observe the preview window in the left

corner while navigating.

After a symbol has been chosen, it is inserted in the current diagram and

gets selected. It then can be moved and connected as usual.

6. Special Functions

6.9

Managing Projects

FluidSIM allows of including various settings and ﬁles in a project ﬁle

with a unique name, thereby facilitating project management. When

opening a project, the previously saved project settings are used as

default. The project menu realizes a quick access of all ﬁles that belong

to a particular project.

Creating a New Project Before a new project is created some preparatory actions to facilitate

project management and to save several process steps at a later stage

must be undertaken.

> Open all ﬁles to be added to the new project. This may include, for

example, preview windows for often used symbols, libraries as well

as circuit ﬁles.

All ﬁles that are open when creating a new project will be automatically

added to the project.

> Select Project New... and enter a ﬁle name for the new project.

Project ﬁles have the extension prj and should, for best results, reside

in the same ct subdirectory as the circuit ﬁles of the project.

After having entered the ﬁle name in the dialog box, the system creates

the project ﬁle with all open ﬁles.

> Close all windows which you don’t need right now, and arrange the

remaining windows according to your preferences.

Any closed windows that belong to the project can be opened at any

time by clicking Files or Overviews in the project menu.

> Save the settings and the window arrangement as default for this

project by clicking Options Save Settings Now .

134 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

Entering Project Properties To enter project data, select Properties... from the Project menu. The text

entered in the description ﬁeld will be displayed in the status line of

the main window while the project is open.

Adding Files to a Project To add a new symbol, a library, or a circuit ﬁle to a project, open or

activate the appropriate window, then click Add Current Window in the

Project menu. Depending on whether the window is a circuit ﬁle or

a preview window, it is automatically added to Files ,Overviews ,and

Presentations respectively.

Removing Files from a

Project

To remove a symbol, a library, or a circuit ﬁle from a project, open or

activate the appropriate window. Then click Delete Current Window in the

Project menu.

Opening Project Files To open the ﬁles and previews (overviews) of a project, go to the

Project menu and click Files ,Overviews ,or Presentations ,whateveris

appropriate. Alternatively, you may open the ﬁles by selecting Open...

from the ﬁle menu or by selecting them from the list of ﬁles that were

last opened, by selecting them from preview windows,orbyusing

“Drag-and-Drop” in the File Manager or Windows Explorer.

6. Special Functions

6.10

Saving Settings

FluidSIM distinguishes between three types of settings: global settings,

circuit diagram speciﬁc settings, and window speciﬁc settings. Although

most of these settings have already been in discussed in preceding

sections, this section comprises the possible settings from FluidSIM and

their relationship to one another.

Global Settings The global settings are found under the Options and the View menu and

belong to the following groups.

Global settings for various display features:

1. View Large Mouse Cursor

Activates or deactivates the large mouse cursor.

2. View Toolbar

Displays or hides the toolbar.

3. View Status Bar

Displays or hides the status bar.

Global settings in the dialog boxes:

1. Options Simulation...

2. Options Sound...

3. Options Didactics...

4. Options Grid...

Other global settings:

1. Options Protect Text Components

Switches the protection for the text components on or off.

2. Options Create Backup Files

Enables or disables the automatic creation of a backup ﬁle for

circuit diagrams. Backup ﬁles have the ﬁle name extension bak.

The backup ﬁles are created when the circuit diagram is saved and

are updated each time the circuit diagram is saved.

3. Options Default Directory on Network

136 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

6. Special Functions

Deﬁnes the default directory for circuit diagrams and presentation

ﬁles. If this option is enabled the default directory for the men-

tioned ﬁles is on the network ﬁle server. Otherwise, the default

directory is on the local PC. This menu entry is available only in the

network version.

4. Options Save Settings on Exit

Determines whether the global settings and the circuit diagram

speciﬁc settings of each open circuit diagram should be saved

before exiting FluidSIM.

Allglobalsettingscanbesavedwith Options Save Settings Now .

By clicking on Save Settings Now under the Options menu, the circuit

diagram speciﬁc settings of the current circuit will also be saved. These

settings then become the default for all new circuit diagrams that are

created. The following settings belong in the circuit diagram speciﬁc

category: display of quantity values, the ﬂow direction indicator, and the

background grid (see next section).

Circuit Diagram-Speciﬁc

Settings

The following belong to the circuit diagram speciﬁc settings:

1. View Quantity Values...

2. View Display Flow Direction

3. View Display Grid

These settings can be adjusted for each open circuit diagram individu-

ally, although they cannot be saved as such. Instead, the user has a way

to deﬁne a default setting for the creation of new circuit diagrams: By

clicking on Save Settings Now under Options , the display settings of the

current circuit diagram are saved as the default. These default settings

apply to the display of quantities, the ﬂow direction indicator, and the

background grid of each newly opened circuit diagram.

The term “current circuit” refers to the selected circuit diagram window.

A selected window will always be fully visible and its title bar will be

highlighted.

6. Special Functions

Window-Speciﬁc Settings The following settings are window speciﬁc:

1. zoom factor

2. window size

3. window position

Window-speciﬁc settings can be saved by clicking on Save Settings Now

under the Options menu.

138 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

7. Help and Advanced Tips

This chapter serves as the ﬁrst place to ﬁnd help, when dealing with

questions that come from working with FluidSIM. The second section of

this chapter provides background information for advanced users.

7.1

The Most Frequently

Occurring Problems

When attempting to perform certain actions, you are prompted to

insert the FluidSIM CD.

FluidSIM cannot ﬁnd certain installation directories on the hard disk.

Probably not all of the software components were loaded at the time

of installation. Either insert the CD or reinstall the missing software

components.

Component cannot be moved or deleted.

Make sure that you are in the Edit Mode ( ); components can only be

moved or deleted in the Edit Mode.

Components cannot be dragged onto the drawing area.

Make sure that you are in the Edit Mode.

Components cannot be moved or deleted in the Edit Mode.

Make sure that you have selected a component and not a

component

connection

A line cannot be drawn between two connections.

Make sure to check the following points:

1. FluidSIM is in the Edit Mode.

2. No other connections are selected.

3. Both connections do not have a blind plug.

4. Both connections are of the same type.

7. Help and Advanced Tips

The parameters of a component cannot be changed.

Make sure that FluidSIM is in the Edit Mode or that the simulation has

been paused ( ).

The hard disk is running non-stop and the simulation is going

slowly.

There is not enough memory available. A workaround is to quit other

running applications or to quit Microsoft Windows®and restart the

computer.

Already drawn lines, which are reported to be superimposed,

cannot be found.

Press the Del key immediately after accepting the message; then draw

a new line.

FluidSIM does not behave normally.

Exit both FluidSIM and Microsoft Windows®, and then restart Microsoft

Windows®and FluidSIM.

You are getting negative values for pressure.

Negative values for pressure mean that from a physical standpoint, the

power supply unit is not providing the necessary output. Often, the

reason is that there is a too high tensile load on a cylinder. In reality this

situation can lead to different reactions, depending on apparent loads

and the power supply unit involved. For this reason FluidSIM simply

indicates a negative pressure value.

140 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

7. Help and Advanced Tips

The pressure drop on a pressure relief valve is higher than its preset

targeted nominal value.

There is really no mistake here: A pressure relief valve has a preset

nominal pressure threshold, which is related to a certain pressure ﬂow.

If the ﬂow should increase beyond this value, a larger pressure drop

will occur, according to the resistance characteristics of the valve. The

pressure relief valve is also not in the position to guarantee a certain

pressure in all circumstances.

Text components cannot be selected.

Make sure that the option Protect Text Components has not been activated.

Valves cannot be switched.

Electrically operated valves can be switched by hand only if no sort of

control signal is applied.

Certain editing functions are not available in the context menu.

The context menu contains a practical subset of possible editing

functions. Probably the operation that you would like to utilize applies

only to one component at a time; if this is the case check to see that

only one component is selected.

There is no pressure drop in the circuit, although a T-connection is

apparently open.

T-connections are considered to be different from other connections: As

an aid in drawing, they must not be provided with blind plugs because

they are automatically closed if no line is connected.

The simulation time runs irregularly, although the slow-motion

factor has been set to 1:1, and “Keep real-time” has been activated.

Both a complex circuit diagram and a slow computer could be reasons

for the inability of FluidSIM to guarantee adherence to real-time.

7. Help and Advanced Tips

At certain connections arrows for the ﬂow direction are not

displayed. The option Display Flow Direction has been activated.

The arrows only appear when a connection actual has a ﬂow passing

through it. This situation is not to be confused with a high pressure at a

connection.

The animation is not repeated, although the “Loop” option has

been activated.

The “Loop” option only applies to an animation that is not contained in

part of a presentation.

FluidSIM is not behaving as expected, and you have already exited

Microsoft Windows®and started FluidSIM new again many times.

Highly likely is that temporary ﬁles are corrupt. Attempt to completely

delete the contents of the fl_sim_h\tmp directory.

Paste is not available from the menu, although a Copy operation

has already taken place.

Only selected objects can be copied to the clipboard. If no objects are

selected, only the picture will be copied to the clipboard.

The playback of the educational ﬁlms appears jerky.

The playback of video sequences on any computer requires quite a

bit of power. Besides that, enlargement of the video window requires

even more complex computations. The following points should be

considered:

1. In the Device menu of the Media Player, under the Conﬁgure... menu,

set the size to normal.

2. Exit all other programs; stop all running simulations and animations

in FluidSIM.

3. Set the number of colors to 256.

142 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

7. Help and Advanced Tips

No educational ﬁlm will start playing.

Video playback requires suitable hardware and software. Moreover,

FluidSIM needs access to the movie ﬁles on the CD-ROM.

The student version of FluidSIM is being loaded each time you start,

although you have purchased the full version.

The FluidSIM CD contains both the student version and the full version

of FluidSIM. During the installation procedure you are asked whether

the full version or the student version shall be installed.

The mouse cursor is not switching as described, especially on top of

connections.

Make sure that the option Large Mouse Cursor has not been activated. The

large mouse cursor is designed to be used with a projector; here the

switching of the mouse cursor is undesirable.

DXF Export... is not available from the menu.

Make sure that you are in the Edit Mode and that the window is not

empty.

The text that was exported using the DXF ﬁlter does not appear as it

did in FluidSIM.

The DXF format does not sufﬁciently support textual objects. I.e.,

CAD programs may not possess the ability to translate all fonts, font

attributes, font colors, and special symbols.

Infeasible pressure values are shown at some connections.

FluidSIM neglects dynamical effects in component behavior. As a result,

no pressure values can be computed in circuit sections that are shut off.

Anyway, to give an idea of the pressure magnitude, FluidSIM performs a

reasonable estimation respecting such values.

7. Help and Advanced Tips

7.2

Tips for the Advanced

User

This section contains some technical information about different

concepts in FluidSIM.

Data Formats of the

Clipboard

When information from a FluidSIM window is copied to the clipboard,

both a meta ﬁle and a bitmap are generated. When pasting into another

application (a word processing program or a drawing program), the

program automatically ﬁnds the format that will contain the most

information. However, it could be intended to insert a circuit diagram,

for example into Microsoft Word®, as a bitmap as opposed to the meta

ﬁle representation. In this case you simply paste the contents of the

clipboard into bitmap editor such as Paintbrush, and then recopy it back

to the clipboard. Following this action, Microsoft Word®then will ﬁnd

the bitmap when pasting from the clipboard.

Media Playback When playing the educational ﬁlms of FluidSIM, the Windows Media

Player is loaded. Further hints are described in the Microsoft Windows®

Help under the media playback topic.

Opening FluidSIM ﬁles via

the Explorer

Normally, to open a ﬁle from within FluidSIM, you would click on Open...

under the File menu. It is also possible to open ﬁles via the Explorer.

There are two possible ways to go about doing this:

1. You can connect ﬁles with FluidSIM that have the same extension,

for example ct. By double clicking on a ﬁle with this extension, it

will be opened by FluidSIM. If FluidSIM is not running at this time, it

will be started by the File Manager.

2. Select the ﬁles that are to be opened in the usual way in the

Explorer. Here the window of the Explorer with the selected ﬁles

should either appear next to an open FluidSIM window or next to

the FluidSIM program icon on the desktop. You can open the ﬁles

by dragging them over FluidSIM.

Opening FluidSIM Files by

Command Line Entry

Besides the possibilities listed above for opening FluidSIM ﬁles, you can

also open ﬁles by entering an appropriate command line. Once in the

Start menu, click on Run... and enter the ﬁle name after the program

name.

144 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

7. Help and Advanced Tips

Reorganization of the

Internal Memory

While working with FluidSIM, particular information is cached in the

memory for performance purposes. In some cases it is desirable to

free up memory or to force a window refresh. By pressing the ESC

key, FluidSIM reorganizes its memory, removes the cached data,

rebuilds the internal data structures, and refreshes all windows. If the

topmost window is a circuit diagram preview window, the contents of

the corresponding directory will also be read as new.

Changing the Sound Files If your computer is equipped with an audio playback facility, sounds

can be played during the changeover of relays, switches, and valves

or during the activation of a buzzer. You can add your own sounds

to replace the preselected ones by replacing the sound ﬁles in the

snd directory. The sound ﬁle for the switches and relays is named

switch.wav, the sound ﬁle for a valve is named valve.wav,and

the sound ﬁle for the activation of the buzzer is named horn.wav.

File Operations via Preview

Windows

Aside from opening circuit diagrams by double clicking on a circuit’s

miniature representation, a preview window does also provide some

File Manager functionality. Analogous to the Edit Mode for objects in

a circuit diagram, the miniaturized circuit diagrams can be selected,

deleted, copied between overview windows (or moved by holding down

the Shift key), copied to the clipboard, or dragged into the a circuit

diagram window.

Please remember, that delete operations and move operations take

place on the ﬁle system. Therefore, if a miniaturized circuit diagram is

deleted, its related ﬁle will also be deleted in the ﬁle system.

Creating Presentation Files This section describes how presentations can be created using a

common text editor: more speciﬁcally, not using FluidSIM.

The ﬁle names of presentation ﬁles have the extension .shw.Ashw ﬁle

has the following structure:

7. Help and Advanced Tips

The ﬁrst line contains the description of the presentation, which also

appears in the selection box. The following lines contain the numbers of

the topics for the presentation in corresponding order. When a shw ﬁle

is created by FluidSIM, the topic numbers are written within brackets,

followedbytheappropriatenameforthetopic.

The shw ﬁle for the presentation named Exercises does appear as

follows:

Exercises

[107.1] Horizontal grinding machine (pump delivery)

[108.1] Bending machine (directly-controlled pressure relief

valve)

[109.1] Roller conveyor (flow resistance)

[110.1] Embossing press (activation of a single acting cylin-

der)

[111.1] Ladle (activation of a double acting cylinder)

[112.1] Paint drying oven (4/3-way valve)

[113.1] Clamping device (closing speed)

[114.1] Hydraulic crane (speed reduction)

[115.1] Feed control for a lathe (speed control)

[116.1] Planing machine (by-pass circuit)

[117.1] Drilling machine (pressure regulator)

The brackets and the topic names can be left out, when the ﬁle is

manually created. I.e., the contents of the presentation Exercises

could look like the following:

Exercises

107.1

108.1

109.1

110.1

111.1

146 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

7. Help and Advanced Tips

112.1

113.1

114.1

115.1

116.1

117.1

FluidSIM automatically inserts the brackets and topic names, if you

select this ﬁle in the presentation dialog box for editing purposes and

then exit the dialog box by clicking on “OK”.

Network Installation of

FluidSIM

If several PCs are running in a network, a complete installation of

FluidSIM must only be performed once, on the network ﬁle system.

Then on the local PCs merely the license information and a few

conﬁguration ﬁles are required. This concept serves several purposes:

the saving of disk space on the local hard disks, the simpliﬁcation of

software maintenance, the quick distribution of circuit diagrams, or the

installation of new releases of FluidSIM.

The installation of the network version happens within the following

steps:

> Perform a standard installation of FluidSIM on the network ﬁle

system. Note that the local PCs must be authorized to read the

FluidSIM ﬁles on the network ﬁle system.

> Use the network option when installing FluidSIM on the other local

PCs by calling the installation program as follows: setup.exe -N

During a local installation, the installation program asks for the network

path of the FluidSIM bin-directory. Thus FluidSIM must have been

installed on the network ﬁle system

before

any local installation can be

performed.

. Help and Advanced Tips

An aside: The PC used during the FluidSIM standard installation on the

network ﬁle system also reads and writes the FluidSIM conﬁguration

ﬁles on the network. Moreover, a FluidSIM de-installation from this PC

will delete the FluidSIM program ﬁles, and, consequently, FluidSIM is no

longer available on the network. If these side effects are to be avoided,

the network installation of FluidSIM can be performed manually:

>InstallFluidSIM

without

the network option on a local PC, using its

local hard drive.

> Copy the entire FluidSIM directory on the network ﬁle system.

>De-install FluidSIM from the local PC. The license connector will

be credited with the license, and the FluidSIM ﬁles reside on the

network without having wasted a license.

> Now perform the local installation procedure as described above.

If local PCs are not equipped with a CD-ROM drive, and if these PCs have

no access to a CD-ROM drive of some other PC, the educational ﬁlms

may also be played from the network ﬁle system: If sufﬁcient disk space

is left on the network ﬁle system, the movie ﬁles can be copied to the

installation folder during the setup procedure

148 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

A. FluidSIM Menus

This chapter contains a complete listing of the menus in FluidSIM and

can be utilized as a quick-reference guide. The term “current circuit”

refers to the selected circuit diagram window. A selected window will

always be fully visible and its title bar will be highlighted.

A.1

File

New Ctrl +N

Opens a new window to create a circuit diagram. The default name

for the new circuit diagram is noname.ct.Ifacircuitwiththisname

already exists, a number is appended to the title noname to create a

unique ﬁle name.

Open... Ctrl +O

Opens the File Selector dialog box, which allows you to select and open

a circuit diagram.

Save Ctrl +S

Saves the current circuit diagram. The circuit diagram window remains

open.

Save As...

Opens the File Selector dialog box, and you can save the current circuit

under a different name. This name appears in the title bar of the circuit

diagram window and becomes the new name for the circuit.

Circuit Preview Ctrl +U

Opens the circuit diagram preview windows. Double clicking on a

miniature circuit diagram will load the circuit. Circuit diagrams can

be selected and deleted in the preview window. When saving circuit

diagrams, the preview window is automatically updated.

In the fluidsim directory, subdirectories can be created for the saving

of circuit diagrams. FluidSIM recognizes all circuit diagram directories

and generates appropriate circuit diagram preview windows.

A. FluidSIM Menus

DXF Export...

Opens the File Selector dialog box, and you can then export the current

circuit diagram in the DXF format. If no new name is given for the

DXF ﬁle, then it is saved under the circuit diagram name with the ﬁle

extension .dxf.

The DXF export ﬁlter allows the graphic information from the circuit

diagram to be exported to other CAD systems.

Parts list Export...

The ﬁle selector box is opened; the contents of the selected parts list is

saved as a text ﬁle.

When ﬁle name has been speciﬁed, another dialog box opens where a

character can be declared as column separator.

Properties...

Opens a dialog box where the circuit properties can be deﬁned.

Drawing Size...

Opens a dialog box where the paper size can be deﬁned.

Print... Ctrl +P

Opens the Print Preview dialog box, which allows you to print the current

circuit diagram with an optional scaling factor.

Previously Opened Files

Displays a list with the eight previously opened ﬁles. When selecting

one entry of this list the associated ﬁle is opened. The list is sorted: The

most recently opened ﬁle forms the topmost entry.

Exit Alt+F4

Quits FluidSIM.

150 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

A. FluidSIM Menus

A.2

Edit

Undo Alt+Backspace

Undoes the last edit step. Up to 128 previous editing steps, which have

been stored, can be made undone.

Redo Alt+Shift +Backspace

Withdraws the last action performed by Edit Undo .Thefunctioncanbe

used up until there are no more undo steps to be redone.

Cut Shift +Del

Cuts the selected components and saves them to the clipboard.

Copy Ctrl +Ins

Copies the selected components to the clipboard. In this way circuit

diagrams and parts of diagrams can be inserted easily as vector

graphics, for example into word-processing applications.

Paste Shift +Ins

Inserts components from the clipboard onto the drawing area of the

current circuit diagram.

Delete Del

Deletes the selected components from the circuit diagram.

If a

connection

is selected and deleted, a possibly connected line or

ﬁtted blind plug is deleted. However, the component is not deleted.

Select All Ctrl +A

Selects all components and lines of the current circuit diagram.

Group Ctrl +G

Groups the selected objects. Groups can be nested by applying the

grouping operation recursively on already existing groups.

Ungroup

Ungroups the selected groups. Each ungroup operation removes only

the outermost group when applied to a selection that contains nested

groups.

A. FluidSIM Menus

Align

Aligns the selected objects.

Rotate

Rotates the selected components in 90° angles.

If only one component is to be rotated (counterclockwise), this action is

accomplished by holding down the Ctrl key and double clicking on the

component. If additionally the Shift key is held down, rotation happens

in a clockwise fashion.

Properties...

Opens a dialog box that contains the parameters for a single, selected

component. This dialog box will also contain an input ﬁeld for a label

name, as long as a label can be assigned to the component.

If a

ﬂuidic line

is selected, a dialog box will appear in which you can

change the line type from the standard line type, “Main Line”, to the

special line type “Control Line”. Note that—aside from a different

appearance—changing line type has no impact respecting simulation.

If a

ﬂuidic connection

is selected, a dialog box will appear containing

input ﬁelds for the selected connection. The input ﬁelds deﬁne which

of the quantities are to be displayed and, in the case of a hydraulic

connection, if the connection is ﬁtted with a blind plug or a mufﬂer.

152 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

A. FluidSIM Menus

A.3

Execute

Check Superﬁcially F6

Checks the current circuit diagram for mistakes in drawing.

Stop F5

Switches the current circuit diagram in the Edit Mode.

Start F9

Starts the simulation or, as the case may be, animation in the current

circuit diagram.

Pause F8

Pauses the current circuit diagram during simulation without leaving

the Simulation Mode. The simulation can then be re-animated from this

point and continue as if it had not been halted.

If Pause is clicked while being in the

Edit Mode

,thecircuitdiagram

switches to the Simulation Mode without starting the simulation. In

this manner, the components’ states can be set before the simulation is

started.

Reset

Sets an already running or paused simulation back to the initial state.

The simulation is immediately restarted.

Single Step

Stops the simulation after it has run only a little bit. The simulation will

run for a short time period and is then paused ( ).Thesinglestep

mode can be applied at any time to an already running simulation.

Simulate until State Change

Starts the simulation until a state change happens; the simulation

is then paused ( ). A state change occurs when a cylinder piston

travels a stop, a valve switches, a relay or a switch is actuated. The

state change mode can be applied at any time to an already running

simulation.

A. FluidSIM Menus

Next Topic

Switches to the next topic in a presentation.

A.4

Library

Hierarchical View

Opens a library window where the FluidSIM components are organized

hierarchically, i. e. within a tree.

Total View

Opens a library window that shows a total view of all FluidSIM

components.

FluidSIM Version 2

Opens a library window that shows the original component library of the

FluidSIM Version 2.

If only these components are used, the constructed circuit diagrams can

be opened and simulated by all previous versions of FluidSIM.

New...

Opens a dialog box for the creation of a user-deﬁned component library.

User-deﬁned component libraries can be rearranged according to

the user’s will—and, in contrast to the FluidSIM standard libraries,

components can be added or deleted from them.

Rename...

Opens a dialog box to rename a user-deﬁned component library.

Delete

Deletes that user-deﬁned component library whose overview window is

currently active.

154 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

A. FluidSIM Menus

A.5

Insert

A hierarchically organized menu from which an object can be selected

and inserted in the current circuit diagram.

Find Component... F3

Opens the dialog for the string-based search of components.

A.6

Didactics

Component Description

Opens the page with the technical description for the selected

component. This page contains the DIN symbol of the component,

a textual description of the component’s function, the connection

designations, and a listing of the adjustable parameters including their

value ranges.

Component Photo

Opens a window containing a photo of the selected component. In the

case that a component cannot exist singularly in a real system, FluidSIM

displays a photo of the assembly group that this component belongs

to. There is no photo for components that do not have a counterpart in

reality.

Component Illustration

Opens for the selected component either a window containing a sec-

tional view or a dialog box with a list of topics relating the component’s

function. In the latter case the selection may include sectional views of

the component, but also illustrations of the component’s usage within

a circuit diagram. For several components, their sectional view can be

animated like a cartoon.

Topic Description

Opens for a window with a didactics material picture, for example a

sectional view of a component or an exercise, the page with the textual

description of the topic.

A. FluidSIM Menus

Hydraulics Basics...

Opens a dialog box that contains a topics list of hydraulics basics. Here,

those overviews, functional illustrations, and animation are comprised

that are useful when teaching basic concepts of hydraulics. By clicking

on a topic in the list, the dialog box closes, and a window with a picture

of the chosen topic appears.

Working Principle...

Opens a dialog box with sectional views that focus on the function of

single components. For several components, their sectional view can

be animated like a cartoon. By double clicking on a topic in the list,

the dialog box closes, and a window with the chosen sectional view

appears.

Exercise...

Opens a dialog box with exercises related to electro-hydraulics. By

double clicking on a topic in the list, the dialog box closes, and a window

with the chosen exercise appears. Each exercise consists of three

pictures, which can be spooled manually or automatically.

Presentation...

Opens a dialog box that can be utilized to recall available presentations

along with creating new presentations. Presentations allow for the

combination of individual topics into a lesson, ideal for teaching

hydraulics.

Extended Presentation...

Opens a dialog box that can be utilized to recall available Microsoft

PowerPoint presentations. The ﬁles of the extended presentations are

located in the ppx subdirectory of your FluidSIM installation. You can

add PowerPoint presentations on your own by copying the respective

“ppt”-ﬁles or “pps”-ﬁles to the ppx subdirectory.

156 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

A. FluidSIM Menus

Educational Film...

Opens a dialog box with educational ﬁlms related to electro-hydraulics.

By double clicking on a topic in the list, the dialog box closes, and the

media playback starts playing the selected ﬁlm.

A.7

Project

New...

The ﬁle selector box is opened, and a new project can be created.

Project ﬁles get the ﬁle extension prj.

Open...

The ﬁle selector box is opened, and a project can selected and opened.

The current project is closed and the standard settings are loaded.

Add Current Window

Adds the current window to the list of project ﬁles.

Delete Current Window

Removes the current window from the list of project ﬁles.

Properties...

Opens a dialog box where the project properties can be deﬁned.

Files

Shows the list of ﬁles that belong to the current project.

Overviews

Shows the list of preview windows that belong to the current project.

Presentations

Shows the list of presentations that belong to the current project.

A. FluidSIM Menus

A.8

View

The functions of the View menu are circuit diagram speciﬁc, that is, they

only apply to the current circuit diagram. Thus it is possible to apply

individually different display options to each circuit diagram, which is

loaded.

Sort Symbols Alphabetically

Sorts the symbols of the current preview window with respect to their

description and extension respectively.

Standard Size

Displays the circuit diagram without enlargement or reduction.

Previous View

Switches between the last view and the current enlargement of the

current circuit diagram.

Fit to Window

Sets the scale factor so that the entire circuit diagram can be displayed

in the window. The proportion between height and width remains

unaltered.

Zoom by Rubber Band

Changes the mouse cursor to a rubber band, allowing a section of a

window to be selected and then enlarged.

Zoom In >

Enlarges the diagram at a factor of 1.4 (√2). To repeat this action twice

means a doubling in the diagram’s size.

158 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

A. FluidSIM Menus

Zoom Out <

Reduces the diagram at a factor of 1.4 (√2). To repeat this action twice

means a cutting in half of the diagram’s size.

Quantity Values... A

Opens a dialog box for the display of quantities. For each of the

quantities “Velocity”, “Pressure”, ..., different types of display options

can be deﬁned (“None”, “Particular”, “All”).

Display Flow Direction D

Turns on or off the arrow as a direction of ﬂow indicator. The arrow for

the direction of ﬂow will be shown near the component connection, that

is,aslongastheﬂowisotherthanzero.

Display counter values and delay times T

Displays or hides the current values of components with counting and

delay behavior.

Display current path numbering and

switching elements table N

Displays or hides the current path numbering and the switching

elements table in electrical circuits.

Show Connection Descriptors C

Enables or disables the display of the component´s connection

descriptors.

Labels...

Opens a dialog box for the label display style. It can be deﬁned whether

or not the labels are drawn framed.

A. FluidSIM Menus

Display Grid G

Activates the background grid, according to the set style. The style of

the grid can be chosen under Options Grid... .

Layers...

Opens a dialog box for renaming and activating the FluidSIM drawing

layers. For drawing object that cannot be simulated, such as texts, DXF

imports, rectangles, circles, state diagrams, or parts lists, up to eight

drawing layers are provided. The FluidSIM components that can be

simulated live always on the drawing layer number one.

Large Mouse Cursor M

Activates or deactivates the large mouse cursor.

Toolbar

Displays or hides the toolbar.

Status Bar

Displays or hides the status bar.

160 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

A. FluidSIM Menus

A.9

Options

Simulation...

Opens a dialog box with settings for the simulation. Here, parameters

such as the maximum recording time, the slow-motion factor, and the

priority are deﬁned.

OPC/DDE Connection...

Brings up a dialog box with OPC and DDE options, respectively. These

settings relate the communication behavior when coupling FluidSIM

with other applications.

Sound...

Opens a dialog box in which the acoustic signal is switched on for the

following component types: switch, relay, valve, and buzzer.

Didactics...

Opens a dialog box with settings for the didactics. These settings

include factors that apply to animation speed and repeat mode.

Grid...

Opens a dialog box allowing you to activate the background grid and

select its style (“Point”, “Cross”, “Line”) and its resolution (“Coarse”,

“Medium”, “Fine”).

Protect Text Components

Enables or disables the protection of text components. Protected text

components can neither be marked nor moved or deleted.

Create Backup Files

Enables or disables the automatic creation of a backup ﬁle for circuit

diagrams. Backup ﬁle names have the extension bak.Thebackupﬁles

are created when the circuit diagram is saved and are updated each time

the circuit diagram is saved.

A. FluidSIM Menus

Default Directory on Network

Deﬁnes the default directory for circuit diagrams and presentation ﬁles.

If this option is enabled the default directory for the mentioned ﬁles

is on the network ﬁle server. Otherwise, the default directory is on the

local PC. This menu entry is available only in the network version.

Save Settings Now

Saves the current global and window speciﬁc settings. Deﬁnes the

circuit diagram speciﬁc settings of the current circuit diagram as the

default settings.

Global settings pertain to the toolbar and the status bar, to the

simulation, sound, didactic, and grid options, to the creation of backup

ﬁles, as well as quitting FluidSIM. Window speciﬁc settings pertain to

zoom levels, window size, and window position. The quantity display,

as well as the ﬂow direction indicator and the background grid are

considered circuit diagram speciﬁc.

Save Settings on Exit

Deﬁnes as to whether or not the current global and window speciﬁc

settings should be saved upon quitting FluidSIM.

162 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

A. FluidSIM Menus

A.10

Window

Cascade Shift +F5

Arranges the circuit diagram windows in an overlapping format.

Tile Horizontally

Arranges the circuit diagram windows next to each other.

Tile Vertically Shift +F4

Arranges the circuit diagram windows below to each other.

Arrange Icons

Arranges the iconiﬁed windows on the desktop.

Window list

Opens a dialog box with all currently opened windows. The windows can

be activated, minimized or closed by clicking the appropriate buttons.

A.11

Contents... F1

Opens a help window pertaining to a list of contents from the FluidSIM

online help.

How to Use Help

Describes how help can be used.

Addendum to the User Manual

Opens a help window pertaining to the additions to the handbook for

FluidSIM. Note that this menu entry must not be available.

About FluidSIM...

Opens the Program Information box about FluidSIM. Among others,

the FluidSIM version number and the number off the license connector

looked up.

B. The Component Library

In FluidSIM each component in the component library is assigned a

physical model. Using these models, FluidSIM ﬁrst creates a global

behavior model of the circuit which is then processed during simulation.

This chapter provides for a short description of the components in Fluid-

SIM’s component library. If the component has adjustable parameters,

their value ranges are given. A number in brackets after the value range

indicates the default setting for the parameter.

164 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

B.1

Hydraulic Components

Service Components

Pump unit

The pump unit supplies a constant volumetric ﬂow.

The operating pressure is limited by the internal

pressure relief valve. The pump unit has two tank

connections.

Adjustable parameters:

Flow: 0 ... 16 l/min (2 l/min)

Operating pressure: 0 ... 350 bar (60 bar)

Pump unit (simpliﬁed)

Simpliﬁed representation of the detailed pump unit.

The component does not have tank connections in

the circuit diagram.

Adjustable parameters:

Flow: 0 ... 16 l/min (2 l/min)

Operating pressure: 0 ... 350 bar (60 bar)

Tank

The tank is integrated into the pump unit and has a

pressure of 0 bar. It can be inserted into the circuit

diagram as an independent component.

Hose with quick-action coupling

The hose is available in 4 lengths: 600 mm, 1000 mm,

1500 mm, and 3000 mm. Dependent on the length

of a hose different resistance values are considered

during simulation.

Adjustable parameters:

Length: 0 ... 3000 mm (600 mm)

B. The Component Library

Diaphragm accumulator with shutoff block

Stores the pressure and is equipped with a pressure

relief valve to prevent overpressure. Note that Flu-

idSIM simpliﬁes dynamical connections during

simulation. In this connection the accumulator

is loaded in time-discrete steps rather than by a

continuous ﬂow.

Adjustable parameters:

Gas pre-charge pressure: 1 ... 350 bar (10 bar)

Nominal pressure: 0 ... 350 bar (60 bar)

at ﬂow: 0 ... 16 l/min (2 l/min)

Filter

The ﬁlter limits the contamination of the ﬂuid

respecting a certain tolerance value in order to reduce

the risk of damage at the components.

Connection (hydraulic)

A hydraulic connection is a place where a hydraulic

line can be attached to. To simplify the line drawing

process, a connection appears as a small circle in Edit

Mode.

Hydraulic connections can be shut by means of a

blind plug. An open hydraulic connection may result

in leaking oil; FluidSIM®3Hydraulicsthuspopsupa

warning message, if some hydraulic connection was

left open.

Note that at each hydraulic connection values for the

ﬂow and pressure can be displayed.

166 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Line (hydraulic)

A hydraulic line links two hydraulic connections.

Note that a hydraulic connection may be a simple

hydraulic connection or a T-junction. A hydraulic

line causes no pressure drop, i. e., it has no ﬂuidic

resistance.

From a drawing point of view, FluidSIM distinguishes

between control lines and main lines. The former

is represented by a dashed line, the latter is

represented by a solid line and establishes the

default case.

Adjustable parameters:

Line Type: One of {Main Line or Control Line} (Main

Line )

T-junction (hydraulic)

A T-junction joins up to three hydraulic lines,thus

having a single pressure potential. Note that T-

junctions are introduced automatically by FluidSIM

when dropping the line drawing cursor onto another

line in Edit Mode.

Conﬁgurable Way Valves Conﬁgurable 2/n way valve

The conﬁgurable 2/n way valve is a way valve with

two connections, where both its body elements and

its operation modes are user-deﬁnable.

Additionally, the hydraulic connections can be closed

with blind plugs.

Conﬁgurable 3/n way valve

The conﬁgurable 3/n way valve is a way valve with

three connections, where both its body elements and

its operation modes are user-deﬁnable.

Additionally, the hydraulic connections can be closed

with blind plugs.

B. The Component Library

Conﬁgurable 4/n way valve

The conﬁgurable 4/n way valve is a way valve with

four connections, where both its body elements and

its operation modes are user-deﬁnable.

Additionally, the hydraulic connections can be closed

with blind plugs.

Conﬁgurable 5/n way valve

The conﬁgurable 5/n way valve is a way valve with

ﬁve connections, where both its body elements and

its operation modes are user-deﬁnable.

Additionally, the hydraulic connections can be closed

with blind plugs.

Mechanically Actuated

Directional Valves

2/2-way stem-Actuated valve (i)

If the cylinder piston actuates the stem, ﬂow is

enabled from P to A.

This valve is derived from a conﬁgurable

2/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

2/2-way stem-Actuated valve (ii)

If the cylinder piston actuate the stem, the ﬂow from

PtoAisshutoff.

This valve is derived from a conﬁgurable

2/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

3/2-way hand-lever valve

In normal position the connection P is closed and A to

T opened. When manually actuated T is shut off and P

to A opened.

This valve is derived from a conﬁgurable

3/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

168 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

4/2-way hand-lever valve (i)

In normal position the connection P is open to B and

A to T. When manually actuated the valve is set to

parallel position.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

4/2-way hand-lever valve (ii)

In normal position the connection P is open to A and

B to T. When manually actuated the valve is set to

crossover position.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

4/3-way hand-lever valve with shutoff position (i)

In normal position all connections are closed. When

manually actuated the valve is set to parallel or

crossover position.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

4/3-way hand-lever valve with shutoff position (ii)

In normal position all connections are closed. When

manually actuated the valve is set to crossover or

parallel position.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

B. The Component Library

4/3-way hand-lever valve with ﬂoating position (i)

In normal position the connections A and B are open

to T. When manually actuated the valve is set to

parallel or crossover position.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

4/3-way hand-lever valve with ﬂoating position (ii)

In normal position the connections A and B are open

to T. When manually actuated the valve is set to

crossover or parallel position.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

4/3-way hand-lever valve with bypass position (i)

In normal position the connections A and B are closed

and P to T opened. When manually actuated the valve

is set to parallel or crossover position.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

4/3-way hand-lever valve with bypass position (ii)

In normal position the connections A and B are closed

and P to T opened. When manually actuated the valve

is set to crossover or parallel position.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

170 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Solenoid-actuated

Directional Valves

4/2-way solenoid valve (i)

In normal position the connection P is open to B

and A to T. When actuated by the control solenoid,

the valve is set to parallel position. If no current is

ﬂowing through the control solenoid, the valve can be

manually actuated.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

4/2-way solenoid valve (ii)

In normal position the connection P is open to A and

B to T. When actuated by the control solenoid, the

valve is set to crossover position. If no current is

ﬂowing through the control solenoid, the valve can be

manually actuated.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

4/3-way solenoid valve with shutoff position (i)

In normal position all connections are closed. When

actuated by the control solenoids, the valve is set

to parallel or crossover position. If no current is

ﬂowing through the control solenoids, the valve can

be manually actuated.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

B. The Component Library

4/3-way solenoid valve with shutoff position (ii)

In normal position all connections are closed. When

actuated by the control solenoids, the valve is set

to crossover or parallel position. If no current is

ﬂowing through the control solenoids, the valve can

be manually actuated.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

4/3-way solenoid valve with ﬂoating position (i)

In normal position the connections A and B are open

to T. When actuated by the control solenoids, the

valve is set to parallel or crossover position. If no

current is ﬂowing through the control solenoids, the

valve can be manually actuated.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

4/3-way solenoid valve with ﬂoating position (ii)

In normal position the connections A and B are open

to T. When actuated by the control solenoids, the

valve is set to crossover or parallel position. If no

current is ﬂowing through the control solenoids, the

valve can be manually actuated.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

172 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

4/3-way solenoid valve with bypass position (i)

In normal position the connections A and B are closed

and P to T opened. When actuated by the control

solenoids, the valve is set to parallel or crossover

position. If no current is ﬂowing through the control

solenoids, the valve can be manually actuated.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

4/3-way solenoid valve with bypass position (ii)

In normal position the connections A and B are closed

and P to T opened. When actuated by the control

solenoids, the valve is set to crossover or parallel

position. If no current is ﬂowing through the control

solenoids, the valve can be manually actuated.

This valve is derived from a conﬁgurable

4/n way valve. You ﬁnd this valve in the component li-

brary “Frequently used Way Valves”, under the Library

menu.

Shutoff Valves Shutoff valve

The shutoff valve can be manually opened or closed.

Adjustable parameters:

Opening level: 0 ... 100 % (100 %)

Check valve

If the input pressure is at least 1 bar (and 5 bar resp.)

higher than the output pressure, the check valve

opens. Otherwise it is shut.

Adjustable parameters:

Pre-tensioning pressure: One of {1, 5} bar (1 bar)

B. The Component Library

Check valve with pilot control

If the input pressure is higher than the output

pressure, the check valve opens. Otherwise it is

shut. In addition, the check valve can be opened

via a control line, allowing ﬂow in both directions.

Shuttle valve

If one of the two input pressures is larger than zero,

the shuttle valve opens (OR function) and the higher

input pressure becomes the output pressure.

Two-pressure valve

If both input pressures are larger than zero, the two-

pressure valve opens (AND function) and the higher

input pressure becomes the output pressure.

Pressure Control Valves Pressure relief valve

In normal position the valve is closed. If the opening

pressure is reached at P, T opens. When the pressure

drops below the preset level, the valve closes again.

The ﬂow direction is indicated by the arrow.

The pressure drop that is caused by a pressure relief

valve that opens depends on its nominal pressure

respecting some deﬁnite ﬂow. Thus, for a precise

behavior speciﬁcation of a pressure relief valve both

its nominal pressure and a ﬂow must be speciﬁed.

Together these values denote a deﬁnite characteristic

curve of the valve.

Adjustable parameters:

Nominal pressure: 0 ... 350 bar (50 bar)

at ﬂow: 0 ... 16 l/min (2 l/min)

174 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Pressure relief valve with pilot control

In normal position the valve is closed. If the opening

pressure is reached at P, T opens. When the pressure

drops below the preset level, the valve closes again.

In simple terms, the pilot pressure is generated by the

input pressure. The ﬂow direction is indicated by the

arrow.

The pressure drop that is caused by a pressure relief

valve that opens depends on its nominal pressure

respecting some deﬁnite ﬂow. Thus, for a precise

behavior speciﬁcation of a pressure relief valve both

its nominal pressure and a ﬂow must be speciﬁed.

Together these values denote a deﬁnite characteristic

curve of the valve.

Adjustable parameters:

Nominal pressure: 0 ... 350 bar (50 bar)

at ﬂow: 0 ... 16 l/min (2 l/min)

Shutoff/counteracting valve

If the opening pressure is reached at the control line

connection, the valve opens from P to T.

Adjustable parameters:

Nominal pressure: 0 ... 350 bar (50 bar)

3-way pressure reducing valve

The pressure reducing valve maintains a constant

output pressure despite ﬂuctuating input pressure.

The output pressure can only be lower than the input

pressure.

Adjustable parameters:

Nominal pressure: 0 ... 350 bar (10 bar)

B. The Component Library

Pressure Switches Analog pressure sensor

The pressure switch takes the pressure and actuates

the associated electrical pressure switch if the preset

switching pressure is exceeded.

Adjustable parameters:

Switching pressure: 0.001 ... 350 bar (30 bar)

Flow Control Valves Throttle valve

The setting of the throttle valve is set by means of

a rotary knob. Please note that by the rotary knob

absolute

resistance value can be set. This means

that, in reality, different throttle valves can generate

different resistance values despite identical settings.

Adjustable parameters:

Opening level: 0 ... 100 % (100 %)

One-way ﬂow control valve

The setting of the One-way ﬂow control valve is set

by means of a rotary knob. A check valve (see check

valve) is located parallel to the throttle valve. Please

note that by the rotary knob no

absolute

resistance

value can be set. This means that, in reality, different

throttle valves can generate different resistance

values despite identical settings.

Adjustable parameters:

Opening level: 0 ... 100 % (100 %)

2-way ﬂow control valve

If the pressure is sufﬁcient, the preset ﬂow is

maintainedto a constant level in the direction of

the arrow.

Adjustable parameters:

Nominal ﬂow: 0.01 ... 16 l/min (1 l/min)

176 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Flow divider valve

The ﬂow divider valve divides the ﬂow from P into two

equal ﬂows at A and B.

Actuators Double acting cylinder

Double acting cylinder with piston rod on one side.

The piston of the cylinder contains a permanent

solenoid which can be used to operate a proximity

switch.

Adjustable parameters:

Force: -1000 ... 1000 Newton (0 Newton)

Max. stroke: 10 ... 6000 mm (200 mm)

Piston position: 0 ... Max. stroke mm (0 mm)

Piston Area: 0,1 ... 805 qcm (2,01 qcm)

Piston Ring Area: 0,05 ... 425 qcm (1,23 qcm)

Double acting cylinder with shock adsorber at stroke

end

The piston of the cylinder is controlled by the

connected pressure loads. The shock adsorber can

be adjusted by means of two adjustment screws. The

piston contains a permanent solenoid which can be

used to operate a proximity switch.

Adjustable parameters:

Force: -1000 ... 1000 Newton (0 Newton)

Max. stroke: 10 ... 6000 mm (200 mm)

Piston position: 0 ... Max. stroke mm (0 mm)

Piston Area: 0,1 ... 805 qcm (2,01 qcm)

Piston Ring Area: 0,05 ... 425 qcm (1,23 qcm)

B. The Component Library

Double acting cylinder with in and out piston rod

and shock adsorber at stroke end

The piston of the cylinder is controlled by the

connected pressure loads. The shock adsorber can

be adjusted by means of two adjustment screws. The

piston of the cylinder contains a permanent solenoid

which can be used to operate a proximity switch.

Adjustable parameters:

Force: -1000 ... 1000 Newton (0 Newton)

Max. stroke: 10 ... 6000 mm (200 mm)

Piston position: 0 ... Max. stroke mm (0 mm)

Piston Area: 0,1 ... 805 qcm (2,01 qcm)

Piston Ring Area: 0,05 ... 425 qcm (1,23 qcm)

Single acting cylinder

By connecting a sufﬁciently high pressure load, the

piston of the cylinder is extended to its stop. To move

the piston back, an external force must be applied.

Adjustable parameters:

Force: -1000 ... 1000 Newton (0 Newton)

Max. stroke: 10 ... 6000 mm (200 mm)

Piston position: 0 ... Max. stroke mm (0 mm)

Piston Area: 0,1 ... 805 qcm (2,01 qcm)

Piston Ring Area: 0,05 ... 425 qcm (1,23 qcm)

Hydraulic motor

The hydraulic motor transforms hydraulic energy into

mechanical energy.

178 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Measuring Devices Manometer

The manometer measures the pressure at its

connection.

Flow meter

The ﬂow meter consists of a hydraulic motor

connected to an RPM gauge.

B.2

Electrical Components

Power Supply

Electrical connection 0V

0V connection of the power supply.

Electrical connection 24V

24V connection of the power supply.

Connection (electrical)

An electric connection is a place where an electric

line can be attached to. To simplify the line drawing

process, a connection appears as a small circle in Edit

Mode.

Note that at each electric connection values for the

voltage and current can be displayed.

Line (electrical)

A electrical line links two electrical connections.

Note that a electrical connection may be a simple

electrical connection or a T-junction. A electrical

line causes no voltage drop, i. e., it has no electrical

resistance.

B. The Component Library

T-junction (electrical)

A T-junction joins up to three electrical lines,thus

having a single voltage potential. Note that T-

junctions are introduced automatically by FluidSIM

when dropping the line drawing cursor onto another

line in Edit Mode.

Signal Devices Indicator light

If current ﬂows, the indicator light is displayed in the

user-deﬁned color.

Adjustable parameters:

Color: One of {16 standard colors} (Yellow )

Buzzer

If current ﬂows, a ﬂashing ring around the buzzer is

shown. Moreover, if “buzzer” is activated in the menu

under Options Sound... , the buzzer is activated if a

sound hardware is installed.

General Switches Break switch

General break switch that is tailored depending on

the type of component that actuates it.

For example, if the break switch is linked via a label to

aswitch-off delay relay, the break switch changes to a

switch-off delay break switch in the circuit diagram.

Make switch

General make switch that is tailored according to the

component that actuates it.

For example, if the make switch is linked via a label to

aswitch-on delayed relay, the make switch changes

to a switch-on delayed make switch in the circuit

diagram.

180 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Changeover switch

General changeover switch that is tailored according

to the component that actuates it.

For example, if the changeover switch is linked

via a label to a switch-on delayed relay,the

changeover switch changes to a switch-on delayed

changeover switch in the circuit diagram.

Delay Switches Break switch (switch-on delayed)

Switch with delayed opening after pickup. Switch-

on delayed break switches are created by using a

general break switch and setting a label.

Make switch (switch-on delayed)

Switch with delayed closing after pickup. Switch-

on delayed make switches are created by using a

general make switch and setting a label.

Changeover switch (switch-on delayed)

Changeover switch with delayed changeover after

pickup. Switch-on delayed changeover switches are

created by using a general changeover switch and

setting a label.

Break switch (switch-off delayed)

Switch with delayed closing after dropout. Switch-

off delayed break switches are created by using a

general break switch and setting a label.

Make switch (switch-off delayed)

Switch with delayed opening after dropout. Switch-

off delayed make switches are created by using a

general make switch and setting a label.

B. The Component Library

Changeover switch (switch-off delayed)

Changeover switch with delayed changeover after

dropout. Switch-off delayed changeover switches are

created by using a general changeover switch and

setting a label.

Limit Switches Limit switch (break)

Switch that is opened by a cam attached to the

cylinder rod. The switch closes immediately when

the cam has passed the switch. Limit switches are

created by using a general break switch and setting a

label.

Switch with roll (break)

Switch that is opened by a cam attached to the

cylinder rod. The switch closes immediately when

the cam has passed the switch. Switches with

roll are created by using a general break switch,

setting a label and selecting the switch type in the

component’s properties dialog.

Reed contact (break)

Switch that is opened by a cam attached to the

cylinder rod. The switch closes immediately when

the cam has passed the switch. Reed contacts

are created by using a general break switch,

setting a label and selecting the switch type in the

component’s properties dialog.

Limit switch (make)

Switch that is closed by a cam attached to the

cylinder rod. The switch opens immediately when

the cam has passed the switch. Limit switches are

created by using a general make switch and setting a

label.

182 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Switch with roll (make)

Switch that is closed by a cam attached to the

cylinder rod. The switch opens immediately when

the cam has passed the switch. Switches with

roll are created by using a general make switch,

setting a label and selecting the switch type in the

component’s properties dialog.

Reed contact (break)

Switch that is closed by a cam attached to the

cylinder rod. The switch opens immediately when

the cam has passed the switch. Reed contacts

are created by using a general make switch,

setting a label and selecting the switch type in the

component’s properties dialog.

Limit switch (changeover)

Switch that is changed over by a cam attached to the

cylinder rod. The switch changes back immediately

when the cam has passed the switch. Limit switches

are created by using a general changeover switch and

setting a label.

Switch with roll (changeover)

Switch that is changed over by a cam attached to the

cylinder rod. The switch changes back immediately

when the cam has passed the switch. Switches with

roll are created by using a general changeover switch,

setting a label and selecting the switch type in the

component’s properties dialog.

Reed contact (changeover)

Switch that is changed over by a cam attached to the

cylinder rod. The switch changes back immediately

when the cam has passed the switch. Reed contacts

are created by using a general changeover switch,

setting a label and selecting the switch type in the

component’s properties dialog.

B. The Component Library

Manually Operated

Switches

Pushbutton (break)

Switch that opens when actuated and closes

immediately when released.

In FluidSIM switches can be actuated permanently

(locked) when continuing to hold down the mouse

button and pushing the Shift key. This permanent

actuation is released by a simple click on the

component.

Pushbutton (make)

Switch that closes when actuated and opens

immediately when released.

In FluidSIM switches can be actuated permanently

(locked) when continuing to hold down the mouse

button and pushing the Shift key. This permanent

actuation is released by a simple click on the

component.

Pushbutton (changeover)

Switch that changes over when actuated and changes

back immediately when released.

In FluidSIM switches can be actuated permanently

(locked) when continuing to hold down the mouse

button and pushing the Shift key. This permanent

actuation is released by a simple click on the

component.

Detent switch (break)

Switch that opens and locks when actuated.

Detent switch (make)

Switch that closes and locks when actuated.

184 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Detent switch (changeover)

Switch that changes over and locks when actuated.

Pressure Switches Pressure switch (break)

Switch that opens when the preset switching

pressure of the hydraulic pressure switch is

exceeded. Pressure switches are created by using

ageneral break switch and setting a label.

Pressure switch (make)

The switch closes when the preset switching

pressure of the hydraulic pressure switch is

exceeded. Pressure switches are created by using

ageneral make switch and setting a label.

Pressure switch (changeover)

The switch changes over when the preset switching

pressure of the hydraulic pressure switch is

exceeded. Pressure switches are created by using

ageneral changeover switch and setting a label.

B. The Component Library

Proximity Switches Magnetic proximity switch

Switch that closes when a solenoid is brought near

by.

In the Simulation Mode the proximity switch can also

be actuated by clicking on it.

Inductive proximity switch

Switch that closes when the induced electro-magnetic

ﬁeld is changed.

In the Simulation Mode the proximity switch can also

be actuated by clicking on it.

Capacitive proximity switch

Switch that closes when its electrostatic ﬁeld is

changed.

In the Simulation Mode the proximity switch can also

be actuated by clicking on it.

Optical proximity switch

Switch that closes when the light barrier is inter-

rupted.

In the Simulation Mode the proximity switch can also

be actuated by clicking on it.

186 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Relays Relay

The relay picks up immediately when current is

supplied and drops out immediately when current

is removed.

Relay with switch-on delay

The relay picks up after a preset time when current is

supplied and drops out immediately when current is

removed.

Adjustable parameters:

Delay time: 0 ... 100 s (5 s)

Relay with switch-off delay

The relay picks up immediately when current is

supplied and drops out after a preset time when

current is removed.

Adjustable parameters:

Delay time: 0 ... 100 s (5 s)

Relay counter

The relay picks up after a predeﬁned number of

current pulses has been counted between the

connections A1 and A2. If a potential is supplied

between the connections R1 and R2, the counter is

reset to its predeﬁned value.

In the Simulation Mode the relay counter can also be

reset by clicking on it.

Adjustable parameters:

Counter: 0 ... 9999 (5 )

B. The Component Library

OPC/DDE Components FluidSIM Output Port

The FluidSIM output realizes the communication with

other applications.

FluidSIM Input Port

The FluidSIM input realizes the communication with

other applications.

B.3

Electrical Components

(American Standard)

Power Supply

Electrical connection 0V (ladder)

0V connection of the power supply.

Electrical connection 24V (ladder)

24V connection of the power supply.

188 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

General Switches Break switch (ladder)

General break switch that is tailored depending on

the type of component that actuates it.

For example, if the break switch is linked via a label to

aswitch-off delay relay, the break switch changes to a

switch-off delay break switch in the circuit diagram.

Make switch (ladder)

General make switch that is tailored according to the

component that actuates it.

For example, if the make switch is linked via a label to

aswitch-on delayed relay, the make switch changes

to a switch-on delayed make switch in the circuit

diagram.

Delay Switches Break switch (switch-on delayed, ladder)

Switch with delayed opening after pickup. Switch-

on delayed break switches are created by using a

general break switch and setting a label.

Make switch (switch-on delayed, ladder)

Switch with delayed closing after pickup. Switch-

on delayed make switches are created by using a

general make switch and setting a label.

Break switch (switch-off delayed, ladder)

Switch with delayed closing after dropout. Switch-

off delayed break switches are created by using a

general break switch and setting a label.

Make switch (switch-off delayed, ladder)

Switch with delayed opening after dropout. Switch-

off delayed make switches are created by using a

general make switch and setting a label.

B. The Component Library

Limit Switches Limit switch (break, ladder)

Switch that is opened by a cam attached to the

cylinder rod. The switch closes immediately when

the cam has passed the switch. Limit switches are

created by using a general break switch and setting a

label.

Limit switch (make, ladder)

Switch that is closed by a cam attached to the

cylinder rod. The switch opens immediately when

the cam has passed the switch. Limit switches are

created by using a general make switch and setting a

label.

Manually Operated

Switches

Pushbutton (break, ladder)

Switch that opens when actuated and closes

immediately when released.

In FluidSIM switches can be actuated permanently

(locked) when continuing to hold down the mouse

button and pushing the Shift key. This permanent

actuation is released by a simple click on the

component.

Pushbutton (make, ladder)

Switch that closes when actuated and opens

immediately when released.

In FluidSIM switches can be actuated permanently

(locked) when continuing to hold down the mouse

button and pushing the Shift key. This permanent

actuation is released by a simple click on the

component.

Pushbutton (changeover, ladder)

Switch that changes over when actuated and changes

back immediately when released.

In FluidSIM switches can be actuated permanently

(locked) when continuing to hold down the mouse

button and pushing the Shift key. This permanent

actuation is released by a simple click on the

component.

190 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Pressure Switches Pressure switch (break, ladder)

Switch that opens when the preset switching

pressure of the hydraulic pressure switch is

exceeded. Pressure switches are created by using

ageneral break switch and setting a label.

Pressure switch (make, ladder)

The switch closes when the preset switching

pressure of the hydraulic pressure switch is

exceeded. Pressure switches are created by using

ageneral make switch and setting a label.

Relays Relay (ladder)

The relay picks up immediately when current is

supplied and drops out immediately when current

is removed.

Relay with switch-on delay (ladder)

The relay picks up after a preset time when current is

supplied and drops out immediately when current is

removed.

Adjustable parameters:

Delay time: 0 ... 100 s (5 s)

Relay with switch-off delay (ladder)

The relay picks up immediately when current is

supplied and drops out after a preset time when

current is removed.

Adjustable parameters:

Delay time: 0 ... 100 s (5 s)

B. The Component Library

B.4

Digital Components

Constants and Connectors

Digital input

Digital inputs are designated with an “I”. In FluidSIM

digital components can be used inside and outside a

digital module.

If a digital input is used inside a digital module, you

can determine the input connector of the digital

module in question with which the digital input shall

be linked by allocating a number “I0” to “I7”. If there

is an analog signal of more than 10V at the chosen

input of the digital module, the digital input is set to

“Hi”.

If a digital input is used outside a digital module,

there is an additional analog electrical connection at

the digital input. If there is an analog signal of more

than 10V at this connection, the digital input is set to

“Hi”.

As an alternative you can click on the digital input

with the left mouse button in order to set it to “Hi”.

Another click resets the value to “Lo”.

Digital output

Digital outputs are designated with an “Q”. The

output connects a digital signal through from its

input to its output. In FluidSIM digital components

can be used inside and outside a digital module.

If a digital output is used inside a digital module, you

can determine the output connector of the digital

module in question with which the digital output shall

be linked by allocating a number “Q0” to “Q7”. If the

status of the digital output is “Hi”, a potential of 24V

is set at the corresponding output connector of the

digital module.

If a digital output is used outside a digital module,

there is an additional analog electrical connection at

the digital output. If the status of the digital output is

“Hi”, a potential of 24 V is set a this connection.

192 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Memory bits

Memory bits are designated with a “M”. Memory

bits are virtual outputs, with a value at their output

analog to that at their input.

When the simulation start is activated, you can deﬁne

by using the property dialog box if the output Q shall

be set to “Lo” or to “Hi”, independent on the input

value. After the simulation start the value at the

output is set to the value of the input.

Logic level HI

At the output Q you have the logic level “Hi”.

Logic level LO

At the output Q you have the logic level “Lo”.

Connection (digital)

An digital connection is a place where a digital line

can be attached to. To simplify the line drawing

process, a connection appears as a small circle in

Edit Mode.

Note that at each digital connection its level “Lo” /

“Hi” can be displayed.

Line (digital)

A digital line links two digital connections. Note that a

digital connection may be a simple digital connection

or a T-junction.

B. The Component Library

T-junction (digital)

A T-junction joins up to three digital lines,thus

having a single digital level. Note that T-junctions

are introduced automatically by FluidSIM when

dropping the line drawing cursor onto another line

in Edit Mode.

Basic Functions AND

The output Q of the AND is only “Hi” when all inputs

are “Hi”, that is, if they are closed. If an input

pin of this module is not connected, its status is

automatically “Hi”.

Edge-triggered AND

The output Q of the edge-triggered AND is only “Hi”

when all inputs are “Hi” and if at least one input was

“Lo” in the previous cycle. If an input pin of this block

is not connected, its status is automatically “Hi”.

NAND (AND not)

TheoutputQoftheNANDisonly“Lo”,whenall

inputs are “Hi”, that is, if they are closed. If an

input pin of this block is not connected, its status

is automatically “Hi”.

NAND With Edge Evaluation

TheoutputQoftheNANDwithedgeevaluationis

only “Hi”, if at least one input is “Lo” and if all inputs

were “Hi” in the previous cycle. If an input pin of this

block is not connected, its status is automatically

“Hi”.

The output Q of the OR is only “Hi”, if at least one

input is “Hi”, that is, if it is closed. If an input pin of

this block is not connected, its status is automatically

“Lo”.

194 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

NOR (OR not)

The output Q of the NOR is only “Hi” when all inputs

are “Lo”, that is, if they are switched off. As soon as

any input is switched on (status “Hi”), the output of

the NOR is set to “Lo”. If an input pin of this block is

not connected, its status is automatically “Lo”.

XOR (exclusive OR)

The output Q of the XOR is “Hi”, if the inputs are

nonequivalent. If an input pin of this block is not

connected, its status is automatically “Lo”.

NOT (Negation, Inverter)

The output Q is “Hi” if the input is “Lo”. The NOT

block is an input status inverter.

Special Functions

B. The Component Library

Digital module

The digital module is used for a compact embedding

of a digital switching circuit into a electrohydraulic

circuit. The digital module offers 8 electrical inputs

and outputs, which transfer their states to its digital

switching circuit in the inner part. Therefore the

digital switching circuit does not need much space

in the electrohydraulic circuit for the display of the

digital module as a rectangle with a total number

of 18 connections. By making a double-click with

the left mouse button on the digital module you

come to the digital circuit in the inner part of the

module. A new window opens. It shows the digital

circuit and can be handled in the usual way. The

standard conﬁguration in the inner part of a new

inserted digital module is a row with 8 inputs and

8 outputs each. They correspond to the inputs and

outputs of the module in the electrohydraulic circuit.

In order to be able to test the digital circuit during

the set-up, it can be simulated separated from the

electrohydraulic circuit. As soon as the processing

window of the digital module is closed or the original

circuit window is put into the foreground, the

previously effected changes in the digital circuit are

automatically adopted into the digital module of the

electrohydraulic circuit. Inside the digital module only

digital components can be inserted. Furthermore, an

encapsulating of additional digital modules inside a

module is not possible. However, you can use several

digital modules in one electrohydraulic circuit. Please

note that the digital circuit inside a digital module

only works correctly if corresponding potentials are

set at the electrical power supply units of the module

(+24 V) and (0 V).

196 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

On delay

An output with on delay is not switched on until a

speciﬁed time has expired.

When the status of input Trg changes from “Lo” to

“Hi”, the on delay time starts.

If the status of input Trg is “Hi” at least for the

duration of the conﬁgured time, the output Q is set

to “Hi” on expiration of this time. The output follows

the input with on delay. The time is reset, when the

status of the input changes again to “Lo” before the

time has expired. The output is reset to “Lo”, when

the status at the input is “Lo”.

Adjustable parameters:

On delay time: 0 ... 100 s (3 s)

Off delay

The output is not reset until a conﬁgured time has

expired.

When the input status turns to “Hi”, the output Q

is switched instantaneously to “Hi”. If the status at

input Trg changes from “Hi” to “Lo”, the off delay

starts. After expiration of the conﬁgured time, the

output is reset to “Lo” (off delay). When the input Trg

is switched on and off again, the off delay restarts.

The input R (Reset) is used to reset the delay time

and the output before the conﬁgured time has

expired.

Adjustable parameters:

Off delay time: 0... 100 s (3 s)

B. The Component Library

On/Off delay

An output with on/off delay is switched on after a

speciﬁed time and is reset on expiration of a second

speciﬁed time.

As soon as the status at input Trg changes from

“Lo” to “Hi”, the conﬁgured on delay time starts. If

the status at input Trg remains “Hi” at least for the

duration of the conﬁgured time, the output Q is set

to “Hi” on expiration of the on delay time (the output

follows the input on delayed). If the status at input

Trg changes again to “Lo”, before the conﬁgured on

delay time has expired, the time is reset. When the

status at input returns to “Lo”, the conﬁgured off

delay time starts.

If the status at the input remains “Lo” at least for the

duration of the conﬁgured off delay time, the output

is set to “Lo” on expiration of that time (the output

follows the input off delayed). If the status at the

input returns to “Hi” before this time has expired, the

time is reset.

Adjustable parameters:

On delay time: 0 ... 100 s (3 s)

Off delay time: 0... 100 s (3 s)

Retentive On delay

A speciﬁed time starts after an input pulse. The

output is set on expiration of this time.

As soon as the status at the input Trg changes

from “Lo” to “Hi”, the speciﬁed time starts. After

expiration on the conﬁgured time, the output Q is set

to “Hi”. Further switching actions at input Trg have

no inﬂuence on the running time. The output and the

time are only reset to “Lo” when the status at input R

is “Hi”.

Adjustable parameters:

On delay time: 0 ... 100 s (3 s)

198 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Latching Relay

Input S sets output Q. Another input R resets the

output Q.

A latching relay is a simple logic memory. The

output value depends on the input states and on

the previous output status.

Pulse Relay

A short one-shot at the input is used to set and reset

the output.

Output Q status is toggled at every “Lo” to “Hi”

transition of the status at input Trg, that is, the output

is switched on or off. Use input R to reset the pulse

relay to initial state, that is, the output is set to “Lo”.

Wiping Relay - Pulse Output

An input signal generates a signal of speciﬁed length

at the output.

The output status is switched to “Hi” after the input

Trg is set to “Hi”. The conﬁgured time is started at

thesametimeandtheoutputremainsset.After

expiration of the conﬁgured time, the output is reset

to the status “Lo” (pulse output). If the input status

changes from “Hi” to “Lo” before the speciﬁed time

has expired, also the output follows immediately with

a with a “Hi” to “Lo” transition.

Adjustable parameters:

Delay time: 0 ... 100 s (3 s)

B. The Component Library

Edge-triggered Wiping Relay

An input signal generates a signal of speciﬁed length

at the output (retriggering).

The output status is switched to “Hi” after the input

Trg is set to “Hi”. The conﬁgured time is started at the

same time. After expiration of the conﬁgured time,

the output Q status is reset to “Lo” (pulse output).

If the input status changes again from “Lo” to “Hi”

(retriggering), before the speciﬁed time has expired,

the time is reset and the output remains switched on.

Adjustable parameters:

Delay time: 0 ... 100 s (3 s)

Timer Switch

With the timer switch you can create timer switches

referring to days, weeks and years. Upon reach

of the speciﬁed on-transition time, the output Q

of the timer switch is set to “Hi” and upon reach

of the speciﬁed off-transition time to “Lo”. If you

have chosen the option “repeat all”, the on and off

transition is repeated each time according to the

speciﬁed repetition time.

Adjustable parameters:

On time: 0 ... 1000 s (10 s)

Off time: 0,1 ... 1000 s (30 s)

Repeat every: 0,1 ... 1000 s (60 s)

200 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

Up/Down Counter

Depending on the conﬁguration of the input Dir, an

internal value is counted up or down through an input

pulse. The output is set when the conﬁgured count

value is reached.

With every status change at the input Cnt from “Lo”

to “Hi”, the internal counter is increased (Dir = “Lo”)

or decreased (Dir = “Hi”) by one unit. If the internal

counter is equal or larger compared to the speciﬁed

value, the output Q is set to “Hi”.

You can use the reset input R to reset the internal

count value and the output to “Lo”. As long as

R=“Hi”, also the output is “Lo” and the pulses at

input Cnt are not counted.

Adjustable parameters:

Counter: 0 ... 9999 (5 )

Symmetric Clock Generator

A timing signal with a conﬁgurable period is given

at the output. Via the duration of the pulses you can

determine the length of the on and off times. Via

the input En (for Enable) you can switch on the clock

generator, that is, the clock generator sets the output

to “Hi” for the duration of the pulse, subsequent the

output to “Lo” for the duration of the pulse and so on,

until the input status is “Lo” again.

Adjustable parameters:

Impulse time: 0,1 ... 100 s (0,5 s)

B. The Component Library

Asynchronous Pulse Generator

The pulse proﬁle of the output can be changed via

the conﬁgurable pulse duration and pulse pause

duration.

It is possible to invert the output with input INV. The

input INV only negates the output, if the block is

enabled via EN.

Adjustable parameters:

Impulse time: 0,1 ... 100 s (3 s)

Impulse pause time: 0,1 ...100 s (1 s)

Frequency Threshold Trigger

The output is switched on and off depending on two

frequencies which can be speciﬁed.

The threshold trigger measures the signals at input

Fre. The pulses are captured across a measuring

interval which can be speciﬁed. If the frequency

measured within the measuring interval higher than

the input frequency, the output Q is switched to “Hi”.

Q is switched again to “Lo” when the measured

frequency has reached the value of the output

frequency or if it is lower.

Adjustable parameters:

On frequency: 0,1 ...10 pulses/sec (6 pulses/sec)

Off frequency: 0,1 ... 10 pulses/sec (2 pulses/sec)

Time interval: 0,1 ... 100 s (5 s)

202 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

B. The Component Library

B.5

Miscellaneous

Connection (mechanical)

A mechanical connection constitutes a place holder

for the label of a valve solenoid. To simplify clicking,

a mechanical connection appears as a small circle in

Edit Mode.

Valve solenoid

The valve solenoid switches the valve.

By means of a label the valve solenoid can be linked

to a valve that is solenoid operated.

Valve solenoid (ladder)

The valve solenoid switches the valve.

By means of a label the valve solenoid can be linked

to a valve that is solenoid operated.

Distance rule

The distance rule is a device for attaching switches

at the cylinder. The labels at the distance rule deﬁne

links to the actual proximity switches or limit switches

in the electrical circuit.

Status indicator

In Edit Mode, the status indicator is automatically

displayed at those components that are actuated in

the circuit’s initial position.

Cam switch

In Edit Mode, the cam switch is automatically

displayed at those mechanically operated way valves

that are actuated in the circuit’s initial position.

B. The Component Library

Text

The concept of text components in FluidSIM gives

the user a way in which to describe components in

diagrams, assign identiﬁcation texts, or to provide

commentary on the diagram. The text and the

appearance of text components can be customized to

the user’s liking.

State diagram

The state diagram records the state quantities of

important components and depicts them graphically.

Parts list

The parts list component creates from the compo-

nents of a circuit diagram a table, which contains for

each component its designation and its description.

Rectangle

Rectangles are graphic primitives, which can also be

used within circuit diagrams.

Ellipse

Ellipses are graphic primitives, which can also be

used within circuit diagrams.

204 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

C. Didactics Material Survey

This chapter provides a comprehensive listing of those parts of the

didactics material in FluidSIM that are not covered by chapter B

“The Component Library”. Basically, this material consists of the

components’ behavior illustrations, the animations, the exercises, and

the educational ﬁlms, which all can be activated under the Didactics

menu.

The subsequent sections are arranged thematically. The icon

indicates that an animation exists for the related topic. The last section

gives an overview of the educational ﬁlms.

C. Didactics Material Survey

C.1

Basics of Hydraulics

1Lathe

Machine-tool construction is a typical area of

application of hydraulics. With modern CNC

machine tools, the tools and workpieces are

clamped by hydraulic means. Feed motions

and the spindle drive can also be hydraulically

powered.

☞This can also serve as an example of hydraulic

circuit with two pressure ranges, for example, 30

bar for machining and 90 bar for clamping.

2Press with elevated reservoir

This is an application in which extremely high

forces are required. Due to the suspended cylinder

and the tractive load, special measures are

required for the activation of the advance stroke.

This in turn requires specially- designed press

drives.

☞A special feature is the elevated reservoir,

which utilizes the static pressure in the pressure

medium.

3Mobile hydraulics: Excavator

On this hydraulic excavator, not only all working

movements (linear drives) but also the propulsion

of the vehicle (rotary drive) are hydraulically

powered. The primary drive of the excavator is

an internal-combustion engine.

☞A model calculation can be used here to

demonstrate an advantage of hydraulics - large

forces with relatively small components.

206 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

C. Didactics Material Survey

C.2

Components of a

Hydraulic Plant

4.1 Structure of a hydraulic system

This simpliﬁed block diagram shows the division

of hydraulic systems into a signal control section

and a hydraulic power section. This signal control

section is used to activate the valves in the power

control section.

☞The material depicted in these electronic slides

is concerned in the main with the hydraulic power

section and the three “levels” of this which are

shown.

4.2 Hydraulic power section

The diagram of the hydraulic power section is

complemented in this case by a circuit diagram to

allow correlation of the various function groups;

the power supply section contains the hydraulic

pump and drive motor and the components for

the preparation of the hydraulic ﬂuid. The energy

control section consists of the various valves

used to provide control and regulate the ﬂow rate,

pressure and direction of the hydraulic ﬂuid. This

drive section consists of cylinders or hydraulic

motors, depending on the application in question.

4.3 Block diagram of a control system

In analyzing and planning an actual control task,

it can be helpful to use a differentiated block

diagram showing the actual levels to be found on

the machine.

☞The light arrows show the signal ﬂow, while the

solid dark arrows show the energy ﬂow.

C. Didactics Material Survey

5.. Interaction of components

The animations show the sequences in a basic

hydraulic circuit in simpliﬁed form - the actuation

and spring return of the ﬁnal control element

(4/2-way valve), the advance and return of the

drive component (double acting cylinder) and the

opening and closing of the pressure relief valve.

☞The representations of the actuator and ﬁnal

control element are based on the relevant circuit

symbols. This can be used as a preparation for the

introduction of circuit symbols.

6.1 Action related numbering

First of all the control chain is numbered

sequentially according to the principle. The ﬁrst

actuator is given the supplementary number

.0 and the associated ﬁnal control element

the supplementary number .1. The remaining

elements get even numbers if they inﬂuence

the advance stroke and uneven numbers if they

inﬂuence the return stroke.

☞The numbering should always be entered in

the circuit diagram and also on the machine to

enable systematic fault-ﬁnding.

6.2 Numbering in accordance with DIN ISO 1219-2

The DIN ISO Standard 1219-2 deﬁnes the code

structure of the components as a string consisting

of the following four parts: number of the plant,

number of the circuit, component designation, and

componentnumber.Iftheentiresystemconsists

of a single plant only, the plant number may be

dropped.

☞(see topic 6.1)

208 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

C. Didactics Material Survey

6.3 Numbering in accordance with parts list

Another method used in practice is to number

all the components in a hydraulic system

consecutively. The numbers then correspond to

the numbers in the parts list.

☞This method is used particularly with complex

controls systems, for which a control-chain-

related numbering system can not be used due

the overlaps involved.

C. Didactics Material Survey

C.3

Symbols

7Circuit symbols for energy transfer (1)

The symbols shown are used in circuit diagrams

for energy transfer and hydraulic-ﬂuid preparation.

☞In the interests of clarity, the lines in the circuit

diagram should be drawn without cross-overs as

far as possible.

8Circuit symbols for energy transfer (2)

The direction of the arrows in the circuit symbols

for the heater and cooler correspond to the

direction of heat ﬂow.

9Circuit symbols for energy conversion

Hydraulic pumps are shown by a circle with a part

representation of a drive shaft. Triangles in the

circles show the direction of ﬂow. The triangles

are shown solid, since pressure ﬂuid is used in

hydraulics.

☞If the pressure medium is gaseous, as in the

case of pneumatics, the triangles are shown in

outline.

10 Circuit symbols for hydraulic motors

The symbols for hydraulic motors are distin-

guished from the symbols for hydraulic pumps

by the fact that the arrows showing the direction of

ﬂow are the other way round.

210 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

C. Didactics Material Survey

11 Circuit symbols for single acting cylinders

Single acting cylinders have one port, i.e. pressure

ﬂuid can be applied only to the piston side. With

these cylinders, the return stroke is produced

either by external force, shown in the symbol by

an opening bearing cap, or by a spring is shown

within the symbol in this latter case.

12 Circuit symbols for double acting cylinders

Double acting cylinders have two ports to allow

pressure ﬂuid to be applied to both cylinder

chambers. The symbol for a differential cylinder

is distinguished from the symbol for a double

acting cylinder by the two lines added to the end

of the piston rod. The area ratio is generally 2:1.

In the case of cylinders with double- ended piston

rods, the symbol shows that the piston areas are

of equal size (synchronous cylinders).

13 Circuit symbols for directional control valves (1)

Designations for directional control valves always

give ﬁrstly the number of ports and then the

number of switching positions. Directional control

valves always have at least two ports and at least

two switching positions. The number of squares

shows the number of possible switching positions

of a valve. Arrows within the squares show the

direction of ﬂow. Lines shown how the ports are

interconnected in the various switching positions

of the valve. The designations always relate to the

normal position of the valve.

C. Didactics Material Survey

14 Circuit symbols for directional control valves (2)

This illustration shows the circuit symbols for 4/2-

and 5/2-way valves.

☞There are two general methods for the

designation of ports, using either the letters P,

T, R, A, B and L or consecutively using A, B, C, D

etc.; the ﬁrst method is the preferred one in the

relevant standard.

15 Circuit symbols for directional control valves (3)

The illustration shows the circuit symbols for 4/3-

way valves with various mid-positions.

16 Circuit symbols for manual operation

The switching position of a directional control

valve can be changed by various actuation

methods. The symbol for the valve is accordingly

supplemented by a symbol indicating the

actuation methods shown, such as pushbuttons

and pedals, a spring is always necessary for

resetting. Resetting can, however, also be

achieved by actuating the valve a second time,

for example in the case of valves with hand levers

and detents.

☞The various actuating methods possible are

listed in DIN ISO 1219.

17 Circuit symbols for mechanical actuation

This illustration shows the symbols for stem or

push button, spring and roller stem.

212 © Festo Didactic GmbH & Co. KG and Art Systems • FluidSIM

C. Didactics Material Survey

18 Circuit symbol for pressure valves

Pressure valves are represented using squares.

The ﬂow direction is indicated by an arrow. The

valve ports can be designated as P (supply port)

and T (tank return port) or as A and B. The position

of the arrow within the square indicates whether

the valve is normally open or normally closed.

Adjustable pressure valves are indicated by a

diagonal arrow through the spring. Pressure

valves are divided into pressure relief valves and

pressure regulators.

19 Circuit symbols for ﬂow control valves

A distinction is made in ﬂow control valves

between types which are affected by viscosity and

those which are unaffected. Flow control valves

unaffected by viscosity are termed oriﬁces. A

2-way ﬂow control valve consists of restrictors,

one adjustable restrictor which is unaffected

by viscosity (oriﬁce) and a regulating restrictor

(pressure compensator). These valves are

represented by a rectangle containing the symbol

for the adjustable restrictor and an arrow to

represent the pressure compensator. The diagonal

arrow through the rectangle indicates that the

valve is adjustable.

20 Circuit symbols for non-return valves

The symbol for non-return valves is a ball which is

pressed against a seat. Delockable non-return

valves are shown by a square containing the

symbol for a non- return valve. The pilot control

for unlocking the non- return valve is indicated

by a broken line at the pilot port. The pilot port is

designated by the letter X.

C. Didactics Material Survey

21 Circuit symbols for measuring devices

The illustration shows the symbols for measuring

devices used in hydraulics.

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C.4

Some Physical

Fundamentals

22 Hydrostatic pressure

Hydrostatic pressure is the pressure created above

a certain level within a liquid as a result of the

weight of the liquid mass. Hydrostatic pressure

is not dependent on the shape of the vessel

concerned but only on the height and density

of the column of liquid.

☞Hydrostatic pressure can generally be ignored

for the purpose of studying hydraulics (exception:

see topic 2).

23 Pressure propagation

If a force F acts on an area A of an enclosed liquid,

a pressure p is produced which acts throughout

the liquid (Pascal’s Law).

☞Hydrostatic pressure has been ignored here.

The term pressure propagation is also used to

mean the pulse velocity in liquids (approx. 1000

m/s).

24 Power transmission

If a force F1is applied to an area A1of a liquid, a

pressure p results. If, as in this case, the pressure

acts on a larger surface A2,thenalargercounter-

force F2must be maintained. If A2is three times

as large as A1, then F2will also be three times as

large as F1.

☞Hydraulic power transmission is comparable to

the mechanical law of levers.

C. Didactics Material Survey

25.1 Displacement transmission (1)

If the input piston of the hydraulic press travels a

distance s1, a volume of ﬂuid will be displaced.

This same volume displaces the output piston by

the distance s2. If the area of this piston is larger

than that of the input piston, the distance s2will

be shorter than s1.

☞Hydraulic displacement transmission is

comparable to the mechanical law of levers.

25.2 Displacement transmission (2)

(see topic 25.1)

26.1 Pressure transfer (1)

The ﬂuid pressure p1exerts a force F1on the

surface A1which is transferred via the piston rod

to the small piston. The force F1thus acts on the

surface A2and produces the ﬂuid pressure p2 .

Since the piston area A2is smaller than the piston

area A1, the pressure p2must be larger than the

pressure p1.

☞The pressure-transfer (pressure-

intensiﬁcation) effect is put to practical use in

pneumatic/hydraulic pressure intensiﬁers and

also in purely hydraulic systems when extremely

high pressures are required which a pump cannot

deliver.

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26.2 Pressure transfer (2)

A pressure-transfer effect also occurs in conven-

tional double acting cylinders with single piston

rod.

☞This effect also causes problems in hydraulics.

If, for example, an exhaust ﬂow control is ﬁtted

to a differential cylinder for the advance stroke,

a pressure- intensiﬁcation effect results in the

piston-rod chamber.

27 Types of ﬂow

A distinction is made between laminar ﬂow

and turbulent ﬂow. In the case of laminar ﬂow,

the hydraulic ﬂuid moves through the pipe in

ordered cylindrical layers. If the ﬂow velocity of

the hydraulic ﬂuid rises above a critical speed, the

ﬂuid particles at the center of the pipe break away

to the side, and turbulence results.

☞Turbulent ﬂow should be avoided in hydraulic

circuits by ensuring they are adequate sized.

28a Diesel effect

A pressure drop to the level of vacuum may occur

at points of restriction, causing precipitation of

the air dissolved in the oil. When the pressure

rises again, oil bursts into the gas bubbles and

spontaneous ignition of the oil/air mixture may

occur.

C. Didactics Material Survey

29 Cavitation

Motion energy is required for an increase in the

ﬂow velocity of the oil at a restriction. This motion

energy is derived from the pressure energy. If the

vacuum which results is smaller than −0.3bar, air

dissolved in the oil is precipitated out. When the

pressure rises again due to a reduction in speed,

the oil bursts into the gas bubbles.

☞Cavitation is a signiﬁcant factor in hydraulic

systems as a cause of wear in devices and

connections.

29a Cavitation

Local pressure peaks occur during cavitation. This

causes the erosion of small particles from the wall

of the pipe immediately after the reduced cross-

section, leading to material fatigue and often

also to fractures. This effect is accompanied by

considerable noise.

30 Input and output power

Various losses occur at the individual devices

within a hydraulic control chain. These consist es-

sentially of mechanical, electrical and volumetric

losses.

☞After an installation has been in service for

some time, there will be a change in particular

in the volumetric efﬁciency of the pump, as the

result, for example, of cavitation (see topic 29).

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C.5

Components of a Power

Unit

31.1 Hydraulic power unit

The hydraulic power unit (power supply unit)

provides the energy required for the hydraulic

installation. Its most important components

are the reservoir (tank) , drive (electric motor),

hydraulic pump, pressure relief valve (safety

valve), ﬁlter and cooler. The hydraulic power unit

may also act as a carrier for other devices (gauges,

directional control valves).

31.2 Hydraulic power unit: Reservoir

The hydraulic reservoir contains the hydraulic ﬂuid

required the operate the installation. Within the

reservoir, air, water and solid matter are separated

out of the hydraulic ﬂuid.

☞The size of the reservoir will depend on the

practical application involved; for stationary

systems, the volume of ﬂuid delivered by the

pump in 3 to 5 minutes can be taken as a guide. In

mobile hydraulic systems, on the other hand, the

reservoir contains only the maximum quantity of

hydraulic ﬂuid required.

32 Externally toothed gear pump

Theincreaseinvolumewhichresultswhenatooth

moves out of mesh produces a vacuum in the

suction area. The hydraulic ﬂuid is conveyed into

the pressure area. The hydraulic ﬂuid is then

forced out of the tooth gaps by the meshing of the

teeth and displaced into the above supply line.

C. Didactics Material Survey

33 Internally toothed gear pump

The inner gear is driven by a motor. The teeth

of the inner wheel drive the outer gear wheel.

The rotary motion creates a vacuum in the gaps

between the teeth, causing hydraulic ﬂuid to be

sucked in. On the other side, the teeth engage

once more and oil is displaced from the tooth

chambers.

33a Internally toothed gear pump

See previous individual illustration.

☞The design can deliver pressures of up to

approx. 175 bar. Hydraulic motors represent the

reverse of the function principle.

34 Circuit diagram: Return ﬂow ﬁlter

An oil ﬁlter situated in the return line to the tank

has the advantage that the ﬁlter is thus easy

to maintain. A disadvantage, however, is that

contamination is removed from the hydraulic ﬂuid

only after it has passed through the hydraulic

components.

☞This conﬁguration is often used.

35 Circuit diagram : Pump inlet ﬁlter

With this conﬁguration, the pump is protected

from contamination. The ﬁlter is, on the other

hand, less easily accessible.

☞If these ﬁlters have a too ﬁne mesh, suction

problems and cavitation effects may occur.

Additional coarse ﬁlters upstream of the pump

are recommended.

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36 Circuit diagram: Pressure line ﬁlter

Pressure ﬁlters can be installed selectively

upstream of valves which are sensitive to

contamination; this also enables smaller mesh

sizes to be used.

☞A pressure-resistant housing is required, which

makes this conﬁguration more expensive.

37 Circuit diagram: Contamination indicator

It is important that the effectiveness of a ﬁlter

can be checked by a contamination indicator.

The contamination of a ﬁlter is measured by the

pressure drop; as the contamination increases,

the pressure upstream of the ﬁlter increases. The

pressure acts on a spring- loaded piston. As the

pressure increases, the piston is pushed against a

spring.

☞There are a number of different display

methods. Either the piston movement is directly

visible or it is converted into an electrical or visual

indication by electrical contacts.

38 Water cooler

With this design of cooler, hydraulic ﬂuid is fed

through tubes over which coolant (water) ﬂows.

The heat which is discharged can be re-used.

☞The operating temperature in hydraulic

installations should not exceed 50 - 60°C, since

this would cause an unacceptable reduction

in viscosity, leading to premature aging of the

ﬂuid. In comparison with air cooling, operating

costs a higher due to the required coolant and the

susceptibility to corrosion. Temperature difference

of up to approx. 35°C can be handled.

C. Didactics Material Survey

39 Air cooler

Hydraulic ﬂuid from the return line ﬂows through a

coiled pipe which is cooled by a fan.

☞The advantages here are simplicity of

installation and low operating costs. The noise

of the fan may be a nuisance (see also topic 38).

40 Heating element

Heaters are often required to ensure that the

optimum operating temperature is reached

quickly. Heating elements or ﬂow preheaters are

used for heating and pre-heating hydraulic ﬂuid.

☞If the viscosity is to high, the resulting increase

in friction and cavitation leads to greater wear.

41 Circuit diagram: Hydraulic power unit

The illustration shows the detailed circuit symbol

for a hydraulic power unit.

☞Since this is an combination unit, a dot/dash

line is placed around the symbols representing the

individual units.

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C.6

Fundamentals of Valves

42 Actuating force

With some types of poppet valves, the actuating

force, which is dependent on pressure and area,

may be very high. In order to avoid this, pressure

compensation may be provided at the valves.

43 Poppet principle

Valves are based either on the poppet principle or

slide principle. In poppet valves, a ball, a cone or

a disc is pressed by a spring against the seat of a

passage. The high pressure per unit area which is

created, means that valves of this kind provide a

very efﬁcient seal. The illustration shows a cone

used as a sealing element.

☞See also topics 69 and 71.

44 Slide principle

This illustration shows the principle of a longitu-

dinal slide valve. In order to allow the piston to

move, it has a certain clearance and ﬂoats in hy-

draulic ﬂuids. Ring grooves ensure an even ﬁlm of

oil and thus pressure equilibrium. The piston can

thus be moved with minimal frictional losses.

☞This type of valve cannot provide a perfect

seal, which means that there is always a certain oil

leakage.

45 Poppet valves

In poppet valves, a ball, cone or occasionally a

disk is pressed against a seat area to act as a

sealing element. Valves of this type provide a very

efﬁcient seal.

C. Didactics Material Survey

46 Piston overlap

The switching characteristics of a valve are

governed by, among other things, its piston

overlap. A distinction is made between positive,

negative and zero overlap. In the case of positive

overlap, the port in question is completely covered

by the piston, while with negative overlap it is

less than completely covered. In the case of zero

overlap, the distances between the control edges

of the piston and of the port are exactly the same.

☞The individual control edges of the pilot piston

can have different overlaps.

47.1 Negative switching overlap

In the case of negative overlap, ﬂow from A to T is

not quite closed when the inlet P is opened. This

means that the pressure at port A rises slowly and

the piston starts gently.

☞In manufacturers’ data sheets, overlap posi-

tions are shown within dotted lines between the

switching positions, or the overlap positions are

shown in color or with a patterned background.

47.2 Positive switching overlap

In the case of positive overlap, the left-hand piston

does not open the passage from P to A until the

tank has been completely isolated by the other

piston. Pressure is immediately fed to the load

device (cylinder or hydraulic motor) with the result

that this starts abruptly.

48 Control edges

The control edges of the pistons are often either

sharp, chamfered or notched. The proﬁling of the

control edges means that the throttling action of

the ﬂow when switching is gradual rather than

abrupt.

☞See also the example in topic 94.

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49 Vertical interconnection system

Vertical interconnection systems(“modular

hydraulics”) mean that less space is required and

that no piping is needed between the components.

The circuit symbols directly marked on the

components give greater clarity in the installation.

C. Didactics Material Survey

C.7

Pressure Valves

50.1 Pressure relief valve (1)

In this design incorporating a poppet valve, a seal

is pressed against the inlet port P by a pressure

spring when the valve is in its normal position.

☞In this situation, for example, an unloaded

piston rod is executing an advance stroke and the

entire pump delivery is ﬂowing to the cylinder.

50.2 Pressure relief valve (2)

As soon as the force exerted by the inlet pressure

at A exceeds the opposing spring force, the valve

begins to open.

☞In this situation, for example, the piston rod is

fully advanced; the entire pump delivery is ﬂowing

at the preset system pressure to the tank.

51.1 PRV used to limit system pressure

This illustration shows a pressure relief valve

within a basic hydraulic circuit (used to control a

double acting cylinder).

☞The resistances at the outlet (tank line, ﬁlter)

must be added to the force of the spring in the

pressure relief valve. See also the animation

“Interaction of components” (topic 5).

51.2 Circuit diagram: PRV used to limit system pressure

This illustration shows the same circuit as the

previous illustration, but with the cut-away view

of the PRV replaced by the appropriate circuit

symbol.

C. Didactics Material Survey

52.. Circuit without brake valve

One application of pressure relief valves is as

brake valves; these prevent pressure peaks

which may otherwise occur as the result of mass

moments of inertia when a directional control

valve is suddenly closed. The animation shows an

(incorrect) circuit in schematic form in which the

working line on the exhaust side has fractured due

to the absence of a brake valve.

☞The next animation (topic 53) shows the

correct circuit.

53 Circuit diagram: Brake valve

This illustration shows the correct circuit for the

problem in topic 52. This circuit incorporates not

only a brake valve on the piston-rod side but also

a non-return valve on the inlet side via which oil

can be taken in from a reservoir during the vacuum

phase following the closure of the directional

control valve.

☞The following animation shows the events

which occur in the two working lines.

53.. Circuit with brake valve

The animation 53.1a shows in schematic form the

behavior of the PRV during the braking phase,

while 53.2a shows the behavior of the non-return

valve (NRV) in the supply line and 53a shows the

two events together in summary.

☞The necessity of the brake valve can be

demonstrated by the preceding animation (topic

52).

C. Didactics Material Survey

54 Circuit diagram: PRV as back-pressure valve

Back-pressure valves counteract mass moments

of inertia with tractive loads. The illustration

shows a circuit with a back-pressure valve on

the piston-rod side. On the return stroke, the PRV

is by-passed by an NRV.

☞The PRV must be pressure-compensated

and the tank port must be capable of carrying a

pressure load.

55 PRV, internally controlled, cushioned

Pressure relief valves often incorporate cushioning

pistons or ﬂow control valves. The cushioning

device shown provides fast opening and slow

closing of the valve. This prevents damage caused

by pressure shocks (smooth valve operation).

☞Pressure shock arise, for example, when the

pump delivers oil in an almost unpressurized

condition and the supply port of the load device is

abruptly closed by a directional control valve.

56.1 PRV, externally controlled (1)

This pressure relief valve controls the ﬂow in

accordance with an external pressure setting.

This pressure acts against an adjustable spring

force. The passage from the supply port P to the

tank port T remains closed as long as no load acts

on the pilot piston.

56.2 PRV, externally controlled (2)

Pressure can be fed to the pilot piston via the pilot

port X. As soon as the pressure force at the pilot

piston exceeds the preset spring force, the pilot

piston is displaced, allowing free ﬂow.

C. Didactics Material Survey

57.1 Sequence valve

The example shows a circuit with a pressure relief

valve used as a pressure sequence valve. The

pressure at the pilot piston of the PRV rises via

the pressure regulator. The PRV opens and the

high-pressure pump delivers directly to the tank.

As soon as the 2/2-way valve opens, the pressure

drops. The pressure relief valve closes and the

high pressure pump is connected to the system.

57.2 Circuit diagram: Sequence valve

This illustration shows the same circuit as the

previous illustration, but with the cut-away view

of the sequence valve replaced by the appropriate

circuit symbol.

58 Pressure relief valve

Actual photograph of a PRV (Fa. Hydronorma).

☞This illustration can be used if no actual

component is available.

59.1 2-way pressure regulator (1)

This valve is normally open. The outlet pressure

(A) acts via a pilot line on the left-hand surface of

the pilot piston against an adjustable spring force.

☞Pressure regulators reduce the inlet pressure

to an adjustable outlet pressure. It is appropriate

to use these in hydraulic installations only if

different pressures are required.

C. Didactics Material Survey

59.2 2-way pressure regulator (2)

When the pressure rises at outlet A, the force at

the left-hand surface of the pilot piston becomes

greater, the piston is displaced to the right and

the throttle gap becomes narrower. This causes a

pressure drop.

☞In the case of slide valves, it is also possible

to design the control edges in such way that the

opening gap increases only slowly. This gives

greater control precision.

59.3 2-way pressure regulator (3)

When the preset maximum pressure is reached,

the throttle point closes completely; the pressure

set on the pressure relief valve is produced at the

inlet P.

59.4 2-way pressure regulator (4)

In the circuit illustrated, the piston rod of the

cylinder is executing an advance stroke. The

pressure at the outlet A of the pressure regulator

is less than the system pressure at P and constant.

59.5 2-way pressure regulator (5)

The piston rod of the cylinder is now in its forward

end position. The pressure at outlet A thus

continuestoriseandthethrottlepointcloses

completely.

C. Didactics Material Survey

60 Circuit diagram: 2-way pressure regulator

The illustration shows the same circuit as the

previous illustration, but with the 2-way pressure

regulator in the form of a circuit symbol.

61 Circuit diagram: 2-way pressure regulator

It is appropriate to use PRVs only when different

pressures are required in an installation. The

mod of operation of pressure regulator will thus

be explained here by taking an example with

two control circuits. The ﬁrst control circuit acts

via a ﬂow control valve on a hydraulic motor

which drives a roller. This roller is used to stick

together multi-layered printed circuit boards. The

second control circuit acts on a hydraulic cylinder

which draws the roller towards the boards at an

adjustable reduced pressure.

☞This example can be used as a preliminary

stage to the introduction of the 3-way PR. If the

2-way PR is closed due to the fact that the preset

maximum pressure has been reached, thickening

of the material of the workpieces would cause an

increase in the pressure on the outlet side of the

PR to a higher value than desired. (See also the

animation for topic 62.)

62.1 3-way pressure regulator (1)

The 3-way pressure regulator can be regarded as

a combination of a 2-way PR and a pressure relief

valve (PRV). The PR is in its normal position here;

only a low pressure has built up at the outlet A.

C. Didactics Material Survey

62.2 3-way pressure regulator (2)

When the pressure at A rises the result of external

conditions, this pressure acts via a pilot line on

the left-hand piston surface of the pilot piston

against an adjustable spring force. Every pressure

increase causes the throttle gap to become

narrower, resulting in a pressure drop.

62.3 3-way pressure regulator (3)

When the maximum preset pressure is reached,

the throttle point closes completely. The pressure

set on the system-pressure limiter is produced at

the inlet P.

62.4 3-way pressure regulator (4)

If the pressure rises above the preset value as the

result of an external load at outlet A, the valve

opens to allow ﬂow from A to the tank port T

(pressure-limiter function).

☞3-way pressure regulators are available with

both positive and negative piston overlap. If a 3-

way pressure regulator is created by combining

a 2-way pressure regulator and a pressure relief

valve, the “overlap” is adjustable.

62.. 3-way pressure regulator

The animation shows both the pressure-regulator

and pressure-limiter function of a 3-way pressure

regulator through the example of a roller which

exerts a constant pressure on moving material of

variable thickness.

☞The ﬁnal control element which is normally

interposed has been omitted here in the interests

of clarity.

C. Didactics Material Survey

63.1 3-way pressure regulator (5)

A 3-way PR is shown here in a functional

representation, incorporated into a model circuit

diagram. The piston rod of the cylinder is subject

to external force and the pressure regulator

provides a pressure-limiter function.

63.2 3-way pressure regulator (6)

The illustration shows the same circuit as the

previous illustration, but with the functional

representation of the 3-way pressure regulator

replaced by a “detailed” circuit symbol.

☞3-way pressure regulators are available with

both positive and negative piston overlap. If a 3-

way pressure regulator is created by combining

a 2-way pressure regulator and a pressure relief

valve, the “overlap” is adjustable.

63.3 Circuit diagram: 3-way pressure regulator

The illustration shows the same circuit as the

previous illustration, but with the standard circuit

symbol for a 3-way pressure regulator.

C. Didactics Material Survey

C.8

Way Valves

64.1 2/2-way valve (1)

The 2/2-way valve has a working port A, a supply

port P and a leakage-oil port L. In the case of the

valve shown here, of slide design, ﬂow from P to A

is closed in the normal position.

☞A relief line leading to the leakage-oil port is

provided to prevent a build-up of pressure in the

spring and piston chambers.

64.2 2/2-way valve (2)

The 2/2-way valve is actuated and the passage

from P to A is open.

☞2/2-way valves are also available which are

normally open from P to A.

65.1 2/2-way valve as by-pass valve

This example shows a 2/2-way valve used as a

by-pass valve; when the 2/2-way valve is actuated,

the ﬂow control valve 0V3 is by-passed, causing

the piston rod of the cylinder to advance at

maximum speed.

65.2 Circuit diagram: 2/2-way valve as by-pass valve

The illustration shows the same circuit as the

previous illustration, but with the functional

representation of the 2/2-way valve replaced

by a circuit symbol.

C. Didactics Material Survey

66 Circuit diagram: 2/2-way valve as ﬁnal control element

In its initial position, the cylinder is advanced.

If the 2/2- way valve 0V1 is actuated, the entire

volumetric ﬂow passes to the tank and piston rod

of the cylinder is reset by the external load m. If

0V1 is not actuated, the system pressure set on

the pressure limiter 0V2 builds up and the piston

rod advances.

☞In the initial position, the pump operates

against the preset system pressure, which has

anunfavorableeffectonthepowerbalanceofthe

circuit shown.

66.. 2/2-way valve as ﬁnal control element

The animations show the actuation and release of

the 2/2-way valve, which causes the piston rod of

the cylinder to advance and retract.

67 Circuit diagram for pressure-less pump recirculation

The part circuit diagram shows a 2/2-way valve

used as a by-pass valve to achieve pressure-less

pump recirculation; if the valve is actuated, the

pump no longer needs to operate against the

preset system pressure.

☞One application of this circuit is with 4/3-way

valves which are closed in their mid-position in

cases where, with the installation operational, it is

desired to switch to pump recirculation (see also

topic 78).

C. Didactics Material Survey

68 Circuit diagram: Pressure stage circuit

The part circuit diagram shows a 2/2-way valve

used as a selector switch for one of two preset

system pressures (“pressure levels”); if the 2/2-

way valve is actuated, ﬂow is enabled to a second

system-pressure limiter.

69.1 3/2-way valve (poppet principle) (1)

The 3/2-way valve has working port A, a supply

port P and a tank port T. Volumetric ﬂow can be

routed from the supply port to the working port or

from the working port to the tank port. The third

port in each case is closed. In the normal position

shown, P is closed and ﬂow released from A to T.

☞See also topic 71 (slide principle).

69.2 3/2-way valve (poppet principle) (2)

The 3/2-way valve is actuated; ﬂow is released

from P to A, the outlet T is closed.

☞3/2-way valves which are normally open from P

to A and T closed are also available.

70.1 3/2-way valve as ﬁnal control element

The circuit shows the 3/2-way valve in a functional

representation as a ﬁnal control element of a

single acting cylinder.

☞The non-return valve protects the pump in

cases where the 3/2-way valve is actuated and the

piston rod is subject to an external load.

C. Didactics Material Survey

70.2 Circuit diagram: 3/2-way valve as ﬁnal control element

The illustration shows the same circuit as the

previous illustration, but with the circuit symbol

for the 3/2-way valve.

70.. 3/2-way valve

The animations show the actuation and release of

the manual pushbutton for a 3/2-way valve, which

causes the piston rod of the cylinder to advance

and retract.

71.1 3/2-way valve (slide principle) (1)

The 3/2-way valve has a working port A, a supply

port P and a tank port T. The volumetric ﬂow can

be routed from the supply port to the working

port, or from the working port to the tank port.

The third port in each case is closed. In the normal

position shown, P is closed and ﬂow is released

from A to T.

☞See also the 3/2-way valve designed on the

poppet principle (Topic 69).

71.2 3/2-way valve (slide principle) (2)

The 3/2-way valve is actuated; ﬂow is released

from P to A, and the outlet T is closed.

☞3/2-way valves which are normally closed from

P to A and T are also available.

C. Didactics Material Survey

72 3/2-way valves as diverter

In addition to their application as ﬁnal control

elements, 3/2-way valves can also be used as

diverters. In this case, port T is connected to a

further device, to which a switch-over can then

be made. The part circuit diagrams show the

facility to switch between the ﬂow control valves

with different settings and between heating and

cooling.

☞The circuit symbol is drawn reversed to

simplify the representation of the circuit diagram.

73.1 4/2-way valve, two pistons (1)

The 4/2-way valve has two working ports A and B,

a supply port P and a tank port T. The supply port

is always connected to one of the working ports,

while the second working port is routed to the

tank. In the normal position, there is ﬂow from P to

BandfromAtoT.

☞In contrast to valves with three pistons, 4/2-

way valves with two pistons do not require a

leakage-oil port (see topic 74).

73.2 4/2-way valve, two pistons (2)

The4/2-wayvalveisactuated,andthereisﬂow

from P to A and from B to T.

☞4/2-way valves are also available which are

normally open from P to A and from B to T.

C. Didactics Material Survey

74.1 4/2-way valve, three pistons (1)

This 4/2-way valve has two working ports A and

B, a supply port P and a tank port T. The supply

port is always connected to one of the working

ports, while the second working port is routed to

the tank. In the neutral position, there is ﬂow from

PtoBandfromAtoT.

☞4/2-way valves with three pistons require

a leakage-oil port, since hydraulic ﬂuid would

otherwise be trapped within the valve.

74.2 4/2-way valve, three pistons (2)

The4/2-wayvalveisactuated,andthereisﬂow

from P to A and from B to T.

75.1 4/2-way valve, three pistons (3)

The circuit shows the 4/2-way valve in functional

representation as a ﬁnal control element of a

double acting cylinder.

☞The non-return valve protects the pump in

cases where the piston rod of the cylinder is

subject to an external load.

75.2 Circuit diagram: 4/2-way valve

The illustration shows the same circuit as the

previous illustration, but with the 4/2-way valve as

a circuit symbol.

C. Didactics Material Survey

76.1 4/3-way valve with pump bypass (1)

From the logic point of view, 4/3-way valves are

4/2- way valves with an additional mid-position.

Therearevariousversionsofthismid-position

(in the mid-position in the example shown, the

supply port P is directly connected to the tank T,

see next illustration). In the switching position

shown, there is ﬂow from P to B and from A to T.

☞4/3-way valves are easy to construct as slide

valves and of complex design as poppet valves.

76.2 4/3-way valve with pump bypass (2)

The4/3-wayvalveisinitsmid-position;thereis

ﬂow from P to T, while A and B are closed. Since

the output from the pump ﬂows to the tank, this

switching position is called pump bypass or also

pump recirculation.

☞In the case of pump bypass, the pump needs

to operate only against the resistance of the valve,

which has a favorable effect on the power balance.

76.3 4/3-way valve with pump bypass (3)

The valve is in its left-hand switching position;

there is ﬂow from P to A and from B to T.

77.1 4/3-way valve with pump bypass (4)

The circuit shows the 4/3-way valve in functional

representation as a ﬁnal control element of a

double acting cylinder. The valve is in its mid-

position; the pump delivery ﬂows via the by-pass

line within the pilot piston to the tank.

☞The non-return valve protects the pump in

cases where the piston rod of the cylinder is

subject to an external load.

C. Didactics Material Survey

77.2 Circuit diagram: 4/3-way valve with pump bypass

The illustration shows the same circuit as the

previous illustration, but with the 4/3-way valve as

a circuit symbol.

77.. 4/3-way valve with pump bypass

The animations show the switching of the 4/3-

way valve into the three switching positions and

the corresponding cylinder movements. During

the advance stroke, movement can be halted by

switching to the mid- position.

☞As appropriate to the application in question, a

circuit of this kind must be equipped with a brake

valve to prevent damage to the installation when

the valve is switched to the mid-position (see also

topic 53).

78.1 4/3-way valve with closed mid-position (1)

From the logic point of view, 4/3-way valves are

4/2- way valves with an additional mid-position.

Therearevariousversionsofthismid-position

(in the mid-position in the example shown, all

ports are closed in the mid- position, see next

illustration). In the switching position shown,

there is ﬂow from P to B and from A to T.

78.2 4/3-way valve with closed mid-position (2)

The4/3-wayvalveisinitsmid-position;allports

apart from the leakage-oil port are closed.

☞In this mid-position, the pump is operating

against the system pressure set on the pressure

relief valve.

C. Didactics Material Survey

78.3 4/3-way valve with closed mid-position (3)

The valve is in its left-hand switching position;

there is ﬂow from P to A and from B to T.

79.1 4/3-way valve with closed mid-position (4)

The circuit shows the 4/3-way valve in functional

representation as a ﬁnal control element of a

double acting cylinder. The valve is in its mid-

position; the pump is operating against the

system pressure set on the PRV.

☞If, with an operational installation, it is desired

to switch to pump recirculation, this can be

achieved by using an additional 2/2-way valve

as a changeover valve (see part circuit-diagram in

topic 67).

79.2 Circuit diagram: 4/3-way valve with closed mid- position

The illustration shows the same circuit as the

previous illustration, but with the 4/3-way valve as

a circuit symbol.

80.1 4/3-way valve: overlap positions (1)

The illustration shows the left-hand overlap

position of a 4/3-way valve with positive overlap

in the mid-position (closed mid-position). This

overlap position is a mixture of positive and

negative overlap; P is connected to A, B and T

are closed.

☞With 4/3-way valves, the types of overlap

positions is generally speciﬁed in the data sheet.

C. Didactics Material Survey

80.2 4/3-way valve: overlap positions (2)

The illustration shows the “right-hand” overlap

position of a 4/3-way valve with positive overlap

in the mid- position (closed mid-position). This

overlap position, too, is a mixture of positive and

negative overlap; P is connected to B, A and T are

closed.

81 Directional control valve

Actual photograph of a directional control valve

with lever actuation (Fa. Denison).

☞This illustration can be used if no actual

component is available.

82 4/3-way module

This 4/3-way module with hand-lever actuation

is used in vertical interconnection systems

(“modular hydraulics”).

☞See also the illustration in topic 49.

C. Didactics Material Survey

C.9

Shutoff Valves

83.1 Non-return valve (1)

Non-return valves block ﬂow in one direction and

allow free ﬂow in the other. In the direction of ﬂow

shown, the sealing element is pressed against a

seat by a spring and the hydraulic ﬂuid.

☞These valves are also available in designs

without springs. Since there must be no leaks in

the closed position, these valves are generally of

poppet design.

83.2 Non-return valve (2)

In the direction of ﬂow shown, the valve is opened

by the hydraulic ﬂuid, which lifts the sealing

element from the seat.

84 Circuit diagram: Pump protection

In this circuit, the non-return valve is used to

protect the pump. This prevents a load pressure

from driving the pump in reverse when the electric

motor is switched off. Pressure peaks do not affect

the pump but are discharged via the pressure

relief valve.

85.1 Graetz block (1)

In the Graetz rectiﬁer circuit (Graetz block),

four non- return valves are combined to form a

function unit. The circuit diagram shows how this

operates in conjunction with a ﬂow control valve;

ﬂow passes through this valve from left to right

during both the advance and return strokes of the

cylinder. The situation during the advance stroke

is shown.

☞During the advance stroke shown here, ﬂow

control is carried out on the inlet side.

C. Didactics Material Survey

85.2 Graetz block (2)

The cylinder is on its return stroke. The rectiﬁer

circuit means that ﬂow once again passes through

the ﬂow control valve from left to right.

☞During the return stroke shown here, ﬂow

control is carried out on the outlet side.

85.. Graetz block

The animation shows the actuation and spring

returnofa4/2-wayvalveandtheﬂowthrough

the Graetz block during the advance and return

strokes.

☞Similar rectiﬁer circuits are also used in

conjunction with line ﬁlters or brake valves.

86.1 Delockable non-return valve (1)

In the cases of delockable non-return valves, ﬂow

in the closed direction can be released by means

of an additional pilot port (X). The illustration

shows the valve in its normal position; ﬂow from B

to A is closed.

86.2 Delockable non-return valve (2)

The released piston is pressurized via pilot port

X. This lifts the sealing element from its seat and

releases ﬂow from B to A.

☞In order to release the valve reliably, the

effective area of the pilot piston must always

be greater than the effective area of the sealing

element. Piloted non-return valves are also

available with lockable non-return function.

C. Didactics Material Survey

87.1 Delockable non-return valve (3)

The model circuit diagram shows how a load

can be positioned by holding a cylinder using a

suitable delockable non-return valve. The valve

becomes active in the return stroke whereby

the restriction on the piston side is released by

actuation of the 3/2-way valve.

☞See also the following animation on this topic.

87.2 Circuit diagram: Delockable non-return valve

The illustration shows the same circuit as the

previous illustration, but with the piloted non-

return valve as a circuit symbol.

87.. Delockable non-return valve

The 4/2-way valve is actuated, the hydraulic ﬂuid

passes through the non-return valve against

the force of the return spring and the piston rod

advances. When the 4/2-way valve is reset, the

outlet on the piston side is closed by the non-

return valve, and the cylinder remains advanced.

The 3/2-way valve is now actuated, the pilot

piston is reversed and the outlet ﬂow released;

the piston rod begins to retract. During the return

stroke, the 3/2-way valve is brought temporarily

into its normal position. This causes the outlet

to be closed again, and the piston rod and load

remain in their current position. When the 3/2-way

valve is actuated again, the piston rod travels to its

retracted end position.

C. Didactics Material Survey

88.1 Delockable double non-return valve (1)

Delockable double non-return valves allow a load

to be positioned reliably with the cylinder at a

standstill, even if eternal leaks exist around the

cylinder piston. When, as in the case, neither of

the inlets A1or A2is pressurized, B1and B2are

closed.

88.2 Delockable double non-return valve (2)

When A1is pressurized, the left-hand sealing

element is lifted from its seat, enabling ﬂow to B1.

At the same time, the pilot piston is displaced to

the right, releasing ﬂow from B2to A2.

☞TheoppositeistruewheninletA2is

pressurized.

89.1 Delockable double non-return valve (3)

The model circuit diagram shows a delockable

double non-return valve used in conjunction with

a 4/3-way valve to allow the vertical positioning

of a load. In the mid-position of the ﬁnal control

element shown, ports A and B are connected to

the tank. This means that the inlets A1and A2of

the double non-return valve are pressure-less and

both cylinder supply lines are closed.

89.2 Circuit diagram: Delockable double non-return valve

The illustration shows the same circuit as the

previous illustration, but with the delockable

double non-return valve as a circuit symbol.

C. Didactics Material Survey

C.10

Flow Valves

90 Needle restrictor

Throttle and oriﬁce valves are used to achieve a

certain pressure drop. This is done by creating a

speciﬁc ﬂow resistance. The needle ﬂow control

valve shown generates considerable friction due

to its long narrowing. This means that the action

of the ﬂow control valve is difﬁcult to adjust due to

the fact that a small adjustment produces a large

change in cross-section.

☞One advantage is the simple and inexpensive

design. Needle ﬂow control valves can be used if

the above- mentioned negative properties can be

ignored for the purposes of a given control task.

91 Gap restrictor with helix

Its short narrowing means that the action of this

gap ﬂow control valve is virtually independent of

viscosity. The helix provides precise adjustability,

since adjustment from fully open to fully closed

requires a 360° turn. The helix is, however, very

costly to produce.

92 Circuit diagram: Flow division using restrictor

Throttle and oriﬁce valves control the volumetric

ﬂow rate in conjunction with a pressure relief

valve. The PRV opens when the resistance of the

ﬂow control valve becomes greater than that of the

opening pressure set on the PRV. This produces a

division of ﬂow.

☞Thevolumetricﬂowtotheloaddevicevaries,

i.e. the action of ﬂow control valves is load-

dependent.

C. Didactics Material Survey

93 Flow control valve

Actual photograph of a ﬂow control valve.

☞This illustration can be used if no actual

component is available.

94.1 One-way ﬂow control valve (1)

The one-way ﬂow control valve is a combination

of an oriﬁce or throttle valve and a non-return

valve. In the closed direction shown of the non-

return valve, the volumetric ﬂow passes via the

variable throttle gap, which creates a considerable

resistance.

☞Speed reduction can be achieved by using a

one-way ﬂow control valve in conjunction with a

pressure relief valve or a variable-deliverypump.

The pressure rises upstream of the ﬂow control

valve until the PRV opens and routes part of the

ﬂow to the tank.

94.2 One-way ﬂow control valve (2)

In the reverse direction, from B to A, ﬂow is

unrestricted, since the ball in the one-way

ﬂow control valve allows free ﬂow (non-return

function).

☞One-way ﬂow control valves are available with

a ﬁxed restrictor and with variable ﬂow control.

C. Didactics Material Survey

95.1 2-way ﬂow control valve (1)

Flow control valves have the task of providing

constant volumetric ﬂow independently of

pressure changes at the inlet or outlet of the

valve. This is achieved ﬁrstly by means of an

adjustable restrictor which is set to the desired

volumetric ﬂow. In order to keep the pressure

drop across the throttle point constant, a second

regulating restrictor (pressure compensator) is

also required. The illustration shows the valve in

its normal position.

☞2-way ﬂow control valves always operate in

conjunction with a pressure relief valve. The part

of the ﬂow which is not required is discharged via

the PRV.

95.2 2-way ﬂow control valve (2)

When ﬂuid ﬂows through the valve, the pressure

drop across the adjustable restrictor is kept

constant by the pressure compensator, which

varies the resistance at the upper throttle point in

accordance with the load at the inlet or outlet.

☞See also the animation for this topic.

96.1 2-way ﬂow control valve (3)

In the case of this ﬂow control valve, the pressure

difference is kept constant by a adjustable

restrictor, i.e. between p1and p2. If the pressure

p3rises as the result of an external load, the

overall resistance of the valve is reduced by

opening the regulating restrictor.

96.2 Circuit diagram: 2-way ﬂow control valve

The model circuit diagram shows the arrangement

of a 2-way ﬂow control valve in the piston-side

supply line in order to achieve a constant feed

speed even under varying load. A non-return valve

is ﬁtted in the by-pass to allow the ﬂow control

valve to be by-passed on the return stroke.

C. Didactics Material Survey

96.. 2-way ﬂow control valve

The advancing piston rod encounters a load half-

way through its stroke. The ﬂow control valve

nonetheless ensures that the advance speed

remains constant. From 0 to 2.5 seconds (shown

at button left) the piston rod is unloaded and the

pressure conditions remain constant. When the

piston rod encounters the load, the pressure p3

rises at the outlet of the ﬂow control valve. (In

order to allow the rapid control operations to be

shown more clearly, the time scale now changes

to 1/100ths of a second.) The ﬂow control valve

brieﬂy raises the pressure p2downstream of the

adjustable restrictor. Following this, the regulating

restrictor moves to the left, and p2falls back to its

original value, i.e. the pressure difference between

p1and p2remains constant. The regulating

operation shown is repeated a number of times,

as the result of which p3increases to 25 bar in

several steps and the regulating restrictor opens

more and more. (At the point at which 25 bar is

reached, the time scale changes back to 0.25

seconds.) The piston rod now travels under load

just as fast as previously without load.

C. Didactics Material Survey

C.11

Hydraulic Cylinders and

Motors

97 Single acting cylinder

In the case of a single acting cylinder, only the

piston side is pressurized with hydraulic ﬂuid.

The cylinder can thus carry out work only in one

direction. The ﬂuid which ﬂows into the piston

chamber causes a pressure to build up the surface

of the piston. The piston travels into its forward

end position. The return stroke is effected by a

spring, the dead weight of the piston rod or an

external load.

98 Plunger cylinder

In the case of plunger cylinders, the piston and

rod form a single component. Due to the design of

the cylinder, the return stroke can only be effected

by external forces. The cylinders can therefore

generally be installed only vertically.

99 Double acting cylinder

In the case of double acting cylinders, both piston

surfaces can be pressurized. A working movement

can thus be performed in both directions.

☞With double acting cylinders with a single-

sided piston rod, different forces and speeds are

obtained on the advance and return strokes due to

thedifferenceinareabetweenthepistonsurface

and annular piston surface.

100 Double acting cylinder with end position cushioning

Cylinder with end position cushioning are used to

brake high stroke speeds smoothly and prevent

hard impacts at the end of the stroke. Shortly

before the end position is reached, the cross-

section for the outﬂow of ﬂuid is reduced by

the built-in cushioning pistons and then ﬁnally

closed. The hydraulic ﬂuid is then forced to escape

through a ﬂow control valve.

C. Didactics Material Survey

101.1 End position cushioning (1)

The piston is a short distance before its end

position; the hydraulic ﬂuid on the piston-rod

side must escape via the adjustable ﬂow control

valve above the piston rod

☞This type of end position cushioning is used

for stroke speed between 6 m/min and 20 m/min.

At higher speed, additional cushioning or braking

devices must be used.

101.2 End position cushioning (2)

The piston rod is on its return stroke; in this ﬂow

direction, the non-return valve below the piston

rod is opened, thus by-passing the ﬂow control

valve. The piston rod retracts at maximum speed.

101.. End position cushioning

The illustration shows ﬁrst the advance of the

piston rod from a mid-position to the forward

end position, with cushioning at the end of the

advance movement. The non-return valve is open

during the return stroke.

☞Animation 101.3a also shows the opening of

the pressure limiter after a certain pressure has

been built up on the outlet side by the cushioning

piston.

102 Double acting cylinder

Actual photograph of a double acting cylinder.

☞This illustration can be used if no actual

component is available.

C. Didactics Material Survey

103.. Automatic bleed valve

When the cylinder is retracted, the piston of the

bleed valve is closed. It is lifted as the piston

rod advances. Air can then escape via the bleed

hole until the hydraulic ﬂuid reaches the piston

and pushes it upwards. In the forward end

position, the piston is pushed fully upwards by

the hydraulic ﬂuid and thus provides an external

seal.

☞Bleed valves should be ﬁtted at the highest

point in a piping system, since this is where any

trapped air will collect.

C. Didactics Material Survey

C.12

Gauges

104 Piston pressure gauge

Pressure gauges operate on the principle that

pressure acting on a given area will produce a

given force. In the case of piston pressure gauges,

the pressure acts on a piston against the force

of a spring. The pressure value is now shown on

a scale either by the piston itself or by a pointer

driven magnetically by the piston.

105 Bourdon-tube pressure gauge

Most pressure gauges operate on the principle

of a Bourdon tube. When hydraulic ﬂuid ﬂows

into the tube, an identical pressure is produced

throughout. Due to the difference in area between

the outer and inner curved surfaces, the tube is

bent. This movement is transferred to a pointer.

☞This type of gauge is not protected against

overload. A cushioning restrictor must be installed

in the inlet connection prevent pressure surges

from damaging the tube.

106 Flow meter

The ﬂow of oil to be measured passes through

a movable oriﬁce. The oriﬁce consists of a

ﬁxed cone and a hollow piston mounted on a

spring. The piston is pressed against the spring

in proportion to the ﬂow rate concerned. The

measuring error of this type of ﬂow meter is

approx. 4%. Measuring turbines, oval disk meters

or toothed-wheel gauges are used when higher

accuracy is required.

C. Didactics Material Survey

C.13

Exercises

107.. Exercise: Horizontal grinding machine (pump delivery)

Problem: The slide on a horizontal grinding

machine is hydraulically actuated. A machine

operator determines that the reciprocating

movement of the machine is no longer reaching

the desired speed. A possible cause of this is

reduced pump delivery. To investigate this, it is

necessary to plot a characteristic curve for the

pump and compare this with the values achieved

during initial commissioning. As an additional

exercise, the circuit diagram and parts list for the

necessary test assembly should be prepared.

Solution: In order to draw the characteristic

curve for the pump, the volumetric ﬂow of

hydraulic ﬂuid delivered by the pump (Q) is plotted

against the operating pressure achieved (p). The

manufacturer’s characteristic curve exhibits a

slight downward gradient, since the new pump

manifests increasing internal leakage losses as

necessary to provide internal lubrication. The

newly-plotted curve shows a clear deviation; the

leakage oil losses have become greater at higher

operating pressures, the volumetric efﬁciency

has become worse. The main reason for this is

pump wear. Regarding the circuit diagram for the

test assembly: The adjustable ﬂow control valve

1V3 is adjusted in such a way that the pressure

gauge 1Z1 shows the desired system pressure.

The pressure relief valve 1V2 is used to limit the

system pressure, while valve 1V1 acts as a safety

valveforthepump.

☞The measured values taken as the basis for

this exercise do not allow for the characteristic

curve of the electric motor. The motor characteris-

tic thus forms part of the calculated error.

C. Didactics Material Survey

108.. Exercise: Bending machine (directly-controlled pressure relief

valve)

Problem: A bending machine is used to bend steel

plates. The bending tools are driven by hydraulic

cylinders. It is now desired to use the bending

machine for considerably thicker steel plates than

before. This requires a hydraulic system pressure

of 45 bar against the previous 30 bar. According

to the manufacturer’s data, the pump used is

suitable for the higher operating pressure. Testing

reveals, however, that the bending process is now

much too slow. In this case, leakage losses in the

piping or directional control valve are ruled out

as the cause of the problem. A directly-controlled

pressure relief valve (PRV) is installed as a safety

valve. Measurements of the volumetric ﬂow (Q)

as a function of pressure (p) are available for this

valve. A characteristic curve can than be used

to determine whether the loss of speed in the

bending process is due to the PRV.

Solution: The volumetric ﬂow which is discharged

to the tank when the PRV opens is entered on

the horizontal axis. The characteristic curve

shows that the opening point of the PRV is 44

bar, although it is set to 50 bar. This means that

part of the pump delivery is diverted at pressures

greater than 44 bar. Pressures of more than 44 bar

are achieved during the bending process. Since,

however, the ﬂow is divided from 44 bar onwards,

the volumetric ﬂow to the cylinder is reduced from

this point and the bending process slows down.

Measure to be taken: The PRTV can be set to 60

bar if the overall installation has been designed for

this higher pressure. Flow diversion will then take

place from a pressure of 54 bar onwards.

☞An alternative solution would be to use a valve

with a different response pressure.

C. Didactics Material Survey

109.. Exercise: Roller conveyor (ﬂow resistance)

Problem: Steel blocks are transported on a roller

conveyor. A hydraulic transfer station makes

it possible to transfer blocks from one track to

another. A pressure of at least 30 bar is required

for the transfer of blocks by means of hydraulic

cylinders. Every component through which the

hydraulic ﬂuid ﬂows represents a resistance and

causes a constant pressure loss. The question is,

what pressure is to be set at the pressure relief

valve.

Solution: The total resistance is the sum of all

the individual resistances. The resistance must

be determined separately for the advance and

return strokes. The overall balances do not

includedataforthepressurelossesatthe4/2-

way valve. These can be determined from the ﬂow

characteristic for the 4/2-way valve, based on

a volumetric ﬂow of 8 l/min. In the calculation,

allowancemustbemadefortheresistanceofthe

directional control valve on the inlet and outlet

sides respectively. Allowance must also be made

for the pressure intensiﬁcation factor of 2:1 in

the case of the differential cylinder. This enables

values to be calculated as shown in the solution

ﬁgure. In the case of the advance stroke, 6 bar

hysteresis for the PRV (see exercise 108) must

be added to the calculated 42.5 bar in order to

ensure that the opening pressure is higher than

the required operating pressure. The value ﬁnally

chosen is 50 bar in order to make allowance for

unknown variables such as pipe elbows and the

static friction in the cylinder.

☞In order to keep pressure losses in large

installations to a minimum, it is advisable to select

valves on the basis of their ﬂow characteristics.

It is better to select a valve which is one size

too large than to accept large pressure losses.

This furthermore reduces wear resulting from

cavitation in the valves.

C. Didactics Material Survey

110.. Exercise: Embossing press (activation of a single acting

cylinder)

Problem: Additional hydraulic components are

to be added to an embossing press to eject the

ﬁnished workpieces. A single acting cylinder

(1A) is to be ﬁtted for this purpose. A proposed

solution in the form of a circuit diagram with a

2/2-way valve is to be examined to see if it is

suitable for this control problem. Following this,

a circuit diagram with a 3/2-way valve as ﬁnal

control element is to be developed and a parts

list prepared. A comparison is to be made of the

behavior of these two circuits during the advance

and return strokes.

Solution: When a 2/2-way valve is used to activate

a single acting cylinder, the ﬁnal control element

must be reversed and the hydraulic power unit

switched off in order to retract the piston rod. The

load acting on the piston rod must be larger than

the resistance of the directional control valve. This

solution cannot be used due to the presence of

the second control chain (embossing cylinder). If a

3/2-way valve is used, a direct switch-over can be

made from the advance stroke to the return stroke

without switching off the hydraulic power unit.

Halting at overlap positions, on the other hand

(which are not required here), would be possible

only by switching off the hydraulic power unit.

☞The non-return valve ﬁtted in each case

protects the pump against oil back-pressure. This

is necessary in case the hydraulic power unit is

switched off with the cylinder advanced and under

load.

C. Didactics Material Survey

111.. Exercise: Ladle (activation of a double acting cylinder)

Problem: Liquid aluminum is transferred from a

holding furnace into a channel leading to a die-

casting machine. A ladle is required for this.

A double acting cylinder is used to enable the

ladle to carry out the appropriate movements. A

circuit diagram is provided for the activation of

the cylinder with a 4/2-way valve as ﬁnal control

element. This must be examined to see if it is

suitable for the control task concerned. The ladle

must not be allowed to dip into the furnace when

the valve is not actuated. A circuit diagram with a

back-pressure valve must be developed to cater

for the case in which the ladle is very heavy.

Solution: The requirements of the exercise are

met by the ﬁrst circuit diagram only if the ladle

represents a light load. If the ladle is very heavy,

the advance speed could rise to an unacceptably

high level during the advance stroke of the piston

rod (ladle moving towards furnace), and the

ladle could as a result plunge too quickly into the

molten metal. This can be prevented by installing

a back- pressure valve in the B line between the

valve and cylinder (tractive load).

☞If, as is required in this exercise, the power

component must positively assume a deﬁned end

position when the installation is at rest, valves

with spring return must be used, as in this case.

Here, a 4/2-way valve with spring return has been

used, since this ensures that the cylinder remains

in the desired position if the hydraulic power unit

is switched on unexpectedly. The required cylinder

diameter and the return speed of the piston rod

can also be calculated as additional optional tasks

in the exercise: see the model calculations in the

textbook.

C. Didactics Material Survey

112.. Exercise: Paint drying oven (4/3-way valve)

Problem: Workpieces are fed continuously

through a paint drying oven on a conveyor belt. In

order to minimize the heat loss through the door,

this should be opened only as much as required by

the height of the workpieces. The hydraulic control

system should be designed so that the door can

be held reliably in position for a long period of

time without slipping down. Firstly, a 4/3-way

valve with suitable mid-position functions should

be selected as a ﬁnal control element. Secondly,

a delockable non-return valve should be provided

in the circuit diagram to act as a hydraulic safety

device to prevent slippage of the door under load

(i.e. its own weight) over a long period of time

as the result of leakage losses in the directional

control valve. The question is, which type of 4/3-

way valve has a suitable mid-position function?

Solution: A 4/3-way valve with an “all ports

closed” mid-position will solve the problem only

if a poppet valve is used. If a slide valve would be

used, the oven door would slip down slowly as the

result of internal leakage losses.

☞The second solution would be to ﬁt a

delockable non- return valve in the supply line

to the piston rod side of the cylinder downstream

of the directional control valve. In order to ensure

that the non-return valve closes immediately when

the door stops, both the outlets A and B of the

directional control valve to the tank must be de-

pressurized (A, B and T connected, P closed).

C. Didactics Material Survey

113.. Exercise: Clamping device (closing speed)

Problem: Workpieces are clamped by a hydraulic

cylinder. The closing speed must be reduced in

order to prevent damage to the workpieces. The

opening speed must, however, be maintained. The

question here is how to incorporate the necessary

one-way ﬂow control valve in the circuit. Possible

solutions must be examined to see what thermal

side- effects occur and to determine the pressure

load placed on the components concerned.

Solution: The advance stroke can as a general

principle be made slower by using either inlet or

outlet ﬂow control. Either solution can be used

in this control; in comparison with outlet ﬂow

control, inlet ﬂow control has the advantage that

no pressure intensiﬁcation will take place. The

oil heated at the throttle point will, however,

then pass through the power component. The

resulting expansion of material is not, however,

of signiﬁcance for this simple vice. If the solution

with outlet ﬂow control is selected, it should be

borne in mind that pressure intensiﬁcation will

take place in accordance with the area ratio of

the differential cylinder of 2:1. The pressure relief

valve will respond, i.e. ﬂow division will occur, only

when a pressure has built up on the piston-rod

side which is approximately twice as high as the

system pressure set on the PRV. The cylinder, ﬂow

control valve and connectors used must therefore

be suitable for this intensiﬁed pressure.

☞Precision drives for machine tools are a good

example of cases in which it is essential to make

allowance for expansion of the material of power

components due to the passage through these of

heated oil.

C. Didactics Material Survey

114.. Exercise: Hydraulic crane (speed reduction)

Problem: Presstoolsofvaryingweightsare

inserted into a press by means of a hydraulic

crane. A double acting cylinder raises and lowers

the load. During the commissioning of the

hydraulic crane, it has become apparent that

the advance speed of the piston rod is too high.

The solutions have been proposed to reduce this

speed; a circuit with exhaust ﬂow control and

a circuit with a back-pressure valve. A suitable

solution must be selected and reasons stated

for this choice. Since the second solution is not

capable of operating in this form, this must be

rectiﬁed by correcting the circuit diagram.

Solution: If the solution with exhaust ﬂow control

is selected, it must be borne in mind that the

cylinder, ﬂow control valve and connectors must

be suitable for this intensiﬁed pressure. The

solution chosen is the circuit with the back-

pressure valve; in this case, the load is clamped

hydraulically and a pressure-intensiﬁcation

effect does not occur, since the pressure can be

adjustable by means of the pressure relief valve as

appropriate to the load. A non-return valve must

be installed to provide a by-pass on the return

stroke.

☞Inlet ﬂow control cannot be used to control

a tractive load; the load forces oil out of the

piston-rod chamber faster than oil can ﬂow into

the piston chamber. Vacuum is created and air will

escape.

C. Didactics Material Survey

115.. Exercise: Feed control for a lathe (speed control)

Problem: The feed movement of a lathe has

previously been carried out manually. In future,

this is to be performed automatically by a

hydraulic control system. The feed movement

must be adjustable and remain constant even

with changing tool loads. Since a simple throttle

valve is not able to provide a constant feed speed

under changing load, a 2-way ﬂow control valve

must be used. On the basis of a circuit diagram

with data for the no- load situation, values for

pressures, pressure differences and feed speed

under load must be added. The circuit diagram

must be modiﬁed to ensure that the ﬂow control

valve is not operative on the return stroke. Finally,

the relationship must be investigated between Q

of the PRV and the feed speed and between ∆p2

and the volumetric ﬂow to the load device.

Solution: In order to prevent the ﬂow control valve

from acting as a resistance on the return stroke,

a non-return valve is installed parallel to this as a

by-pass. The pressure at the PRV remains constant

despitetheeffectoftheload.Theoutletﬂowfrom

this is therefore a constant 7 l/min. A constant

volumetric ﬂow Q at the PRV in turn means a

constant volumetric ﬂow to the load device and

thus constant feed speed. Regarding the last

question: No matter whether operation is with

or without a load, the pressure drop ∆p2at the

adjustable throttle remains constant. A constant

pressure drop means a constant volumetric ﬂow.

☞Regarding the necessity for the non-return

valve in the by-pass: When ﬂow passes through 2-

way ﬂow control valves in the reverse direction,

they act either as ﬂow control valves if the

regulating restrictor is fully open or non-return

valves if the regulating restrictor is closed.

C. Didactics Material Survey

116.. Exercise: Planing machine (by-pass circuit)

Problem: The sliding bed of a parallel planing

machine is actuated with the aid of a hydraulic

control system. The power section of this

hydraulic control system consists of a double

acting differential cylinder. The area ratio of

the full piston surface of this cylinder to the

annular piston surface is 2:1. Since the piston-

rod chamber is only half the volume of the piston

chamber, the return stroke is twice as fast as the

advance stroke. Machining has previously been

carried out only during the advance stroke. In

future, working movements are to be carried out

in both directions. To make this possible, the

hydraulic control system must be modiﬁed so that

forward and return strokes are at the same speed.

The speed should now also be adjustable. The

connecting lines should be added to the given

circuit diagram. The mode of operation of the

circuit in the three switching positions should

be described and the various piston speeds and

forces compared.

Solution: In order to achieve the same speed on

the advance and return strokes, a differential

circuit (by-pass circuit) can be used with

differential cylinders with an area ratio of 2:1.

Picture 116.2 shows the principle of a by-pass

circuit with a 3/2-way valve. In the case of

the parallel planing machine, the necessary

differential circuit can be achieved by using

the mid-position of a 4/3-way valve (A, B and P

connected, T closed). In this switching position

(advance stroke), the piston speed and force

are twice as high as in the right-hand switching

position (return stroke). In the left-hand switching

position, on the other hand, the advance stroke is

half as fast and the force twice as great as in the

other two switching positions. The speed for the

advance and return strokes can be adjusted by

means of a ﬂow control valve ﬁtted upstream.

C. Didactics Material Survey

116.. continued Exercise: Planing machine (by-pass circuit)

☞It should also be noted that only half the force

is availableon the advance stroke at the mid-

position. In the case of a tractive load, the by-pass

position has the advantage that the piston is

hydraulically clamped. Differential circuits are

used not only as synchronization circuits but

also as rapid-traverse circuits when, for example,

different speeds are required in the same direction

with constant pump delivery. If it is desired to

calculate forces and piston speeds using concrete

values, the model values given in the TP 501

textbook can be used for this purpose.

C. Didactics Material Survey

117.. Exercise: Drilling machine (pressure regulator)

Problem: The drill feed and clamping device of a

drilling machine are hydraulically actuated. The

hydraulic control system contains two cylinders,

a clamping cylinder 1A and a feed cylinder 2A.

The clamping pressure at cylinder 1A must be

adjustable, since different workpiece clamping

forces are required. A pressure regulator is used

for this. The return stroke of the clamping cylinder

must be at maximum speed. The drilling feed

must be adjustable for various feed speeds,

which must however remain constant under

varying load. It should also be noted that the

drive spindle ﬁtted to the piston rod of the drilling

cylinder acts as a tractive load. The return stroke

of the drilling cylinder should also be at maximum

speed. A circuit should be drafted with the above-

mentioned characteristics.

C. Didactics Material Survey

117.. continued Exercise: Drilling machine (pressure regulator)

Solution: Pressure regulators can as general

principle be used to reduce the general system

pressure in a part of a hydraulic installation. If

we consider the two control chains for the drilling

machine without pressure regulation, we can

observe the following undesirable effects: When

1V1 is actuated, the workpiece is ﬁrst clamped

at full system pressure. If 2V1 is now actuated,

the system pressure will drop to the operating

pressure of the drilling cylinder. The same applies

to the pressure at the clamping cylinder. If the

circuit is expanded to include the pressure

regulator 1V3, this enables the clamping pressure

to be adjusted. The system pressure upstream

of the PRV will, however, continue to fall during

the advance stroke of 2A. In order to maintain the

preset clamping pressure at outlet A of the PRV

reliably, the pressure at inlet P must be higher

than this. This can be achieved by ﬁtting the

additional ﬂow control valve 0V2 upstream of the

ﬁnal control element 2V1. Maximum return-stroke

speed is achieved for the clamping cylinder by

means of 1V2, which is used to by-pass 1V3. The

ﬂow control valve 2V3 means that the advance-

stroke speed of the drilling cylinder is independent

of load and adjustable. Due to the tractive load

of the attached spindle, however, an additional

PRV must be ﬁtted as a back-pressure valve.

The non-return valves 2V2 and 2V5 provide a by-

pass during the return stroke and allow maximum

speed to be achieved during this.

☞A parts list can be speciﬁed to help in the

drafting of this circuit.

C. Didactics Material Survey

C.14

Extensions

118a Refreshment break

Announcement of a short break.

☞Describe the objectives of the next session

indicating what activities will take place. Also,

review the achievements of the current session.

119 Lunch break

Announcement of a longer break

☞Describe the objectives of the next session

indicating what activities will take place. Also,

review the achievements of the current session.

C. Didactics Material Survey

C.15

Educational Films

No. Title Length

1Introduction 3:20

2 Fundamentals: Pressure ﬂuids 2:02

3 Fundamentals: Pressure and Flow Rate 2:41

4 Fundamentals: Transmission of Force and Displacement 1:35

5 Fundamentals: Pressure Transmission 0:53

6 Fundamentals: Types of Flow 2:10

7 Basic Design of Hydraulic Systems 1:13

8 The Hydraulic Power Unit 3:26

9 Hydraulic Drives 6:58

10 Valves 3:12

11 Valves: Directional Control Valves 10:39

12 Valves: Non-Return Valves 1:59

13 Valves: Pressure Control Valves 4:24

14 Valves: Flow Control Valves 4:23

15 Representation of Hydraulic Systems in Circuit Diagrams 2:58

C. Didactics Material Survey

C.16

Standard Presentations

For several topics useful presentations have been provided within Fluid-

SIM. The following table lists the titles of the predeﬁned presentations.

Presentation Title

All topics sorted by number

Applications

Components of a hydraulic system

Graphic and circuit symbols

Fundamental physical principles

Components of the power supply section

Valves in general

Pressure valves

Directional control valves

Non-return valves

Flow control valves

Hydraulic cylinders and motors

Measuring devices

Break and lunch

Exercises

D. Messages

This section contains information about the messages that may appear

from FluidSIM while working in the Edit Mode, the Simulation Mode, or

while saving circuit diagrams.

D.1

Electrical Errors

Simulation aborted. A short-circuit was detected in an electrical

circuit.

The positive and negative poles of a voltage source are directly

connected without a load (indicator light, buzzer, relay, or control

solenoid). The short circuit must be eliminated before simulation can

take place.

D.2

Drawing Errors

Objects are placed outside the drawing area.

At least one object has been placed outside the drawing area. After

acknowledging the dialog box the respective objects are shown

selected. Either change the papersize or place the selected objects

inside the marked drawing area.

Open connections.

At least one component has an open hydraulic connection. After

acknowledging the dialog box, all components with an open hydraulic

connection are selected. If the simulation should be started, FluidSIM

automatically ﬁts blind plugs to open connections.

Incompatible connections are superimposed.

When two connections are superimposed, FluidSIM automatically

connects them. When these two connections do not go together, a

warning message is given.

Superimposed lines.

At least two lines are superimposed. After acknowledging the dialog

box, these line segments are selected.

D. Messages

Lines through components.

At least one line is passing through a component. After acknowledging

the dialog box, the appropriate components are selected.

Lines through connections.

At least one line is crossing through a connection to which the line is not

connected. After acknowledging the dialog box, these lines are selected.

Superimposed components.

At least two components are superimposed. After acknowledging the

dialog box, these components are selected.

Duplicate or incompatible labels.

A label has been used incorrectly. After acknowledging the dialog box,

the appropriate components are selected. To set the circuit diagram into

simulation, other labels will have to be chosen.

There are components with the same description.

The same description has been assigned to more than one component.

After acknowledging the dialog box the respective components appear

selected. Modify the component description(s), or, as the case may be,

rearrange them such that their assignment becomes deﬁnite.

There have been warnings. Start simulation anyway?

This prompt appears when any of the above drawing errors can be found

in the circuit diagram. If the simulation is started while connections are

open, FluidSIM will supply these open connections with blind plugs.

D. Messages

There is no cylinder close to the distance rule.

A distance rule can only be given a label when it is assigned to a

cylinder. Move the distance rule near a cylinder, so that it snaps into

place. Now a label can be entered by double clicking the measuring

scale.

No superﬁcial errors detected.

The circuit diagram does not contain any of the above described drawing

errors.

D.3

Operating Errors

No objects found.

You tried to check a circuit diagram for drawing errors or to start the

simulation; but there are no components located in the current window.

Objects cannot be deleted from the FluidSIM standard libraries.

Create a new library if you want to set up a custom library.

Objects can neither be added nor deleted from the FluidSIM

standard

libraries

. However, new custom libraries can be created instead, which

contain merely your preferred selection of components (see Section

6.8).

Thevaluerangeof ’abc’ is x...x.

The value range for the ﬁeld has been exceeded. Make sure to observe

the indicated limits.

D. Messages

D.4

Opening and Saving Files

The circuit diagram has been changed. Save current changes?

You want to close a circuit diagram window or quit FluidSIM. Since the

last save, changes have been made to the current circuit diagram.

The ﬁle ’ abc ’ already exists. Replace?

A circuit diagram with the name name.ct already exists on the hard

disk. To save the current circuit diagram, you must either change the ﬁle

name, or the already existing ﬁle will be replaced with the new circuit

diagram.

Cannot save DXF ﬁle.

The ﬁle (either the current circuit diagram or the component library)

cannot be saved due to insufﬁcient disk space or a write-protected disk.

Unknown ﬁle format.

The ﬁle cannot be opened since its format is not supported by FluidSIM.

Cannot open ﬁle ’ abc ’.

FluidSIM cannot open the ﬁle because Microsoft Windows®refuses

access to the ﬁle. Either the ﬁle does not exist or is locked by another

application.

’ abc ’ does not exist. Create?

You have tried to open a ﬁle that does not exist. However, the ﬁle can be

opened as a new ﬁle.

The ﬁle ’ abc ’ can not be deleted.

You have tried to delete a ﬁle that does not exist or is write-protected.

D. Messages

Circuit ’ abc ’ is already opened. Close this window before?

You want to save a circuit diagram under another name. There is,

however, already another open window with this name. If you close

this window, the ﬁle will be replaced.

D.5

System Errors

Simulation aborted. The circuit is too large.

The size of circuit diagrams that can be simulated is bound. You must

reduce the number of components.

Internal capacity of FluidSIM exceeded.

The previous action exceeded the capacity of the internal memory. The

action cannot be completed.

No more windows available.

Microsoft Windows®cannot provide any more windows most likely

because the system resources have been exhausted.

Memory capacity exceeded. Quit other running applications.

There is not enough memory readily available to complete the

parameter calculations. To make more memory available, other circuit

diagrams should be closed, along with any other Microsoft Windows®

programs that are running. Then attempt to run the simulation again.

When there is no other possibility to free up memory, the virtual memory

can be increased. Microsoft Windows®then utilizes a section of the hard

drive to increase the memory. However, as a result the execution speed

of the program decreases greatly. It would be wiser to extend the main

memory by increasing the computer’s RAM.

D. Messages

This version is not registered. Please repeat the installation

procedure.

You have tried to start an unlicensed version of FluidSIM. Most likely

you have changed your system conﬁguration, or important system

ﬁles have become corrupt. Attempt to reinstall FluidSIM into the same

directory. If there is a problem with the re-installation, you will receive a

message on the screen pertaining to the problem. Notify Festo Didactic

GmbH & Co. KG of the error or the problem.

Out of memory. Please save changed circuits and quit FluidSIM.

While completing an operation (for example loading a circuit diagram,

displaying a component photo, rebuilding the desktop) an error in the

memory occurred. FluidSIM could not cancel the operation in a proper

manner. You are recommended to quit FluidSIM because the program’s

stability cannot be assured. However, it is still possible to save changes

to circuit diagrams before quitting FluidSIM.

Fatal error. Please save changed circuits and quit FluidSIM.

A program error has occurred. Please save changes to any open circuit

diagrams, quit FluidSIM and Microsoft Windows®,andrestart.

The circuit filename.ct has not been saved when the last

FluidSIM session was terminated improperly. Shall this ﬁle be

recovered?

FluidSIM has been terminated in an unexpected manner. However, a

backup ﬁle was written from which an actual version of the unsaved

circuit can be constructed. If the question is answered with “Yes” a

window with the recovered circuit is opened; however, the original

circuit remains unchanged. You then can decide if to whether the

recovered circuit shall be saved under the original name.

Index

Symbols 29

29,149

21,149

149

41,149

120,150

47,151

32,151

50,151

158

159

65,153

27,153

24,153,205

27,153

153

154

51,152

Index

2/n way valve

conﬁgurable 167

3/n way valve

conﬁgurable 167

4/n way valve

conﬁgurable 168

5/n way valve

conﬁgurable 168

A activation 11

actuation

of switches 26

of valves 43,70

without detent 56

without lock 43

alignment 51

AND

digital 194

animation

component 89

loop mode 90

of diagram symbols 42

Asynchronous Pulse Generator

digital 202

Bbackgroundgrid

default setting 137

display/hide 55

set type 55

Index

blind plug

delete 53

ﬁt automatically 66,273

set manually 53

Ccamswitch 203

CD-ROM drive 11

check valve

with pilot control 174

without pilot control 173

circle 204

circuit diagram

backup 136

creation 29

current 137,149

default directory 136

drawing mistake 64

load 21

print 120

save 275

simulate 24

superﬁcial checking 64

too large 276

click,

see

mouse click 1

clipboard

data format 144

general 50

command line 144

Compatibility

LOGO 79

component

actuation 56

animation 89

animation within circuit 42

connect 35

Index

copy 50

delete 32,274

description 85

in clipboard 50

in selection 47

insert 50

move 31

permanent actuation 56

photo 86

properties 68,76,115

rotate 51

rotate selection 51

sectional view 87,94,107

select 32

superimposed 64,273

usage in circuit 87

with label 69

component library

build 129

create 129

new 129

rearrange 126

using 126

component parameter

adjustable 76

general 76

components

group 55

same description 273

ungroup 56

computer power 25,57

connection

close 60

digital 193

electrical 179

Index

general 35

hydraulic 166

incompatible 272

mechanical 203

open 53,64,272,273

properties 60

quantities 60

superimposed 64,272

Connection

Digital 79

context menu 20,50

context sensitive 85

counter

electrical 187

counteracting valve 175

current path

numbering 58

cycle 112

cylinder

distance rule problem 274

double acting 177,178

single acting 178

smooth movement 78

D DDE

communication 80,82

in 188

options 82

out 188

de-installation 17

default directory 136

delay switches 181,189

detent switch

break 184

changeover 185

Index

make 184

diagram

new 46

print tiled 46

dialog

project 135

dialog box

diagram 47

drawing layers 109

drawing size 46

DXF symbol 125

ellipse 112

exporting parts lists 119

import DXF ﬁle 123

label 71

paper size 46

parts list 118

rectangle 110

valve editor 34,52

diaphragm accumulator 166

didactics

animation speed 107

basic hydraulics 206

component description 85

component photo 86

cylinder 252

educational ﬁlm 105,270

exercise 95

exercises 256

extensions 269

ﬂow valves 248

gauge 255

hydraulic plant 207

hydraulics basics 91

motor 252

Index

physical fundamentals 215

power unit 219

presentation 98

presentations 271

pressure valves 226

sectional view 87,94,107

settings 107

shutoff valves 244

symbols 210

topic description 90

valves 223

way valves 234

Digital Basic Functions 194

Digital Components 192

Digital Constants and Connectors 192

Digital module 196

Digital Special Functions 195

DIN standard 85

directional valves

manually actuated 168–170

3/2-way 168

4/2-way 169

4/3-way 169,170

solenoid 171–173

4/2-way 171

4/3-way 171–173

stem-actuated

2/2-way 168

directories of FluidSIM 15

distance rule

general 203

problem 274

usage 72

dongle 11

drag-and-drop 30,144

Index

drawing

new 46

print tiled 46

size 46

drawing area

objects outside 272

drawing layers 109

drawing mistake 64

DXF

export 122

import 123

E Edge-triggered AND

digital 194

Edge-triggered Wiping Relay

digital 200

edit

redo 47

several circuits 56

undo 47

Edit Mode

activate 56

exit 24

educational ﬁlm

CD-ROM drive 11

general 105

overview 270

Einfügen

Suchen 131

electrical components 179

american standard 188

ladder diagram style 188

electro-hydraulics 66

ellipse 112,204

error

Index

fatal 277

message 272

exercise

bending machine 257

clamping device 262

drilling machine 267,268

drying oven 261

embossing press 259

feed control 264

grinding machine 256

hydraulic crane 263

ladle 260

overview 95

planing machine 265,266

roller conveyor 258

Explorer 144

Fﬁle

create 275

delete 275

open 144,275

replace 275

save 275

save as... 276

unknown format 275

ﬁlm,

see

educational ﬁlm 1

Filter 166

ﬂow control valve 176

ﬂow direction indicator

default setting 137

general 61

ﬂow divider valve 177

ﬂow meter 179

Frequency Threshold Trigger

digital 202

Index

G graphic primitives 110

cycle 112

ellipse 112

rectangle 110

square 110

grid,

see

background grid 1

group

components 55

objects 55

H help on problems 139

digital 193

hose 165

hydraulic motor 178

hydraulics basics 91

I Input

digital 192

insert

parts list 116

installation

FluidSIM 11

FluidSIM in network 147

L label

at component 67

at distance rule 73

display style 71

duplicate 273

frame 71

incompatible 273

ladder diagram 188

large mouse cursor

Index

activate/deactivate 136

Latching Relay

digital 199

license 277

license connector 11

limit switches 182,190

line

automatic creation 58

color 25,77

crosses connection 273

delete 51

digital 193

draw 35

electrical 179

hydraulic 167

move 37

set type 53

superimposed 64,272

thickness 26

through component 273

digital 193

LOGO

Compatibility 79

loop mode

animation 90

presentation 108

M main memory

minimum 11

reorganization 145

small 57

manometer 179

measuring devices 179

media playback 107,144

Index

Media Player 144

memory

exceeded 276

out of 277

Memory bits

digital 193

context sensitive 85

messages 272

miscellaneous 203

model formulation 25

mouse click

double 23,50,53,60,68,69,72,74,76,115

double with Ctrl key 51

left 10

right 20,50

with Ctrl key 47

with Shift key 56

NNAND

digital 194

NAND With Edge Evaluation

digital 194

network

default directory 136

installation 147

option 136,147

NOR

digital 195

NOT

digital 195

numbering

current path 58

Index

Oobjects

alignment 51

group 55

ungroup 56

Off delay

digital 197

On delay

digital 197

On/Off delay

digital 198

One-way ﬂow control valve 176

online help 163

OPC

communication 80,82

in 188

options 82

out 188

options 161

digital 194

Output

digital 192

P paper

size 46

parts list 116–118,204

export 119

power supply

connection (0V) 179,188

connection (24V) 179,188

presentation

creation 99

edit 99

ﬁle format 145

loop mode 108

Index

play 98

topic switching 107

presentations

overview 271

pressure reducing valve 175

pressure relief valve

misbehavior 141

with pilot control 175

without pilot control 174

pressure switches 176,185,191

circuit diagram 120

preview 120

setup 121

window contents 120

Printer

select 121

project 134

adding ﬁles 135

opening ﬁles 135

properties 135

removing ﬁles 135

property,

see

component or connection 1

proximity switches 186

Pulse Relay

digital 199

pump unit 165

simpliﬁed 165

within circuit 39

pushbutton

break 184,190

changeover 184,190

make 184,190

Qquantity

Index

close to zero 61

default settings 137

display 59,137

units of measure 10

quit

unexpected 277

RRAM,

see

main memory 1

real-time proportional 26

recover

circuit 277

rectangle 110,204

registration 277

relay

counter 187

delay time 74

general 74

number of pulses 74

simple 187,191

switch-off delayed 187,191

switch-on delayed 187,191

Retentive On delay

digital 198

rubber band 47,54

S scrollbar 20

service components 165

settings

circuit diagram speciﬁc 136

didactics 107

global 136

save 61,136

save on exit 137

simulation 77

window speciﬁc 136

Index

short circuit 272

shutoff valve 173,175

signal devices

buzzer 180

indicator light 180

simulation

DDE 80

different modes 28

existing circuits 21

Label designation 78

line color 77

OPC 80

parallel 56

piston movement 78

precision 26

real-time 78

settings 77

slow-motion factor 78

start 273

Simulation

Digital Technique 79

Simulation Mode

activate 24

exit 27,56

pause 27

reseting parameters 27

slow-motion factor 78

sound

activate 77

change ﬁle 145

square 110,204

state diagram 204

state values

diagram 62

recording 62

Index

status bar

display/hide 136

of FluidSIM 20

status indicator 203

superﬁcial checking 64

switch

at cylinder 72

automatic altering 75

capacitive 186

coupling 74,75

general

break 180,189

changeover 181

make 180,189

inductive 186

limit

break 182,190

changeover 183

make 182,190

manually actuated

break 184,190

changeover 184,185,190

make 184,190

optical 186

pressure

break 185,191

changeover 185

hydraulic symbol 176

make 185,191

reed contact 183

Reed contact 182

solenoid 186

switch-off delayed

break 181,189

changeover 182

Index

make 181,189

switch-on delayed

break 181,189

changeover 181

make 181,189

with roll 182,183

switching element

table 58

symbol

DXF 125

Symmetric Clock Generator

digital 201

T T-connection 40,58

T-junction

digital 194

electrical 180

hydraulic 167

table

switching element 58

tank 165

text component

general 114,204

protect 114

throttle valve 176

Timer Switch

digital 200

toolbar

display/hide 136

of FluidSIM 19

topic description 90

Two-pressure valve 174

Uundo 47

ungroup

Index

components 56

objects 56

units,

see

quantity 1

Up/Down Counter

digital 201

Vvaluerange

exceeded 274

valve

conﬁgurable 167,168

editor 34,52

valve solenoid 203

American standard 203

valves

conﬁgurable 167

directional 168

ﬂow control 176

pressure 174

shutoff 173

way valves 167

video,

see

educational ﬁlm 1

W warning message 272

way valve

conﬁgurable 167,168

Wechselventil 174

window

arrange 163

not available 276

print contents 120

Wiping Relay

digital 199

Index

XXOR

digital 195

Z zoom

circuit diagram 54

component library 54

time-distance diagram 54

with rubber band 54

FluidSIM 3.6 Hydraulics 104 0561C FL SIM H

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