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Chapter 1 Jun2017

This document provides an introduction to pneumatic systems. It defines pneumatics as using compressed air to generate mechanical force and motion. Some common applications of pneumatics mentioned include packaging, conveying materials, clamping, punching, bending, and machining. The document also discusses the advantages and disadvantages of using compressed air. The main components of a pneumatic system are described as the air compressor, dryer, receiver, service unit, control valves, and actuators.

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Kubheran Selvathurai
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64 views102 pages

Chapter 1 Jun2017

This document provides an introduction to pneumatic systems. It defines pneumatics as using compressed air to generate mechanical force and motion. Some common applications of pneumatics mentioned include packaging, conveying materials, clamping, punching, bending, and machining. The document also discusses the advantages and disadvantages of using compressed air. The main components of a pneumatic system are described as the air compressor, dryer, receiver, service unit, control valves, and actuators.

Uploaded by

Kubheran Selvathurai
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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CHAPTER 1: INTRODUCTION

TO PNEUMATIC SYSTEM
DJJ 5123
PNEUMATIC & HYDRAULICS
COMPRESSED AIR
➤ The 3rd largest energy source
➤ Originates from the atmosphere
➤ Used in every industry
DEFINITION OF PNEUMATIC
➤ Pneumatics – GREEK terminology
➤ pneu – a breath of air
➤ matics – flow power
➤ The use of compressed air in order to generate force that can
produce mechanical movement/power trasmission
➤ Penggunaan angin mampat untuk menghasilkan daya yang
boleh digunakan untuk menjana pergerakan secara mekanikal
APPLICATION
OF
PNEUMATICS
Packaging
Feeding
Transfer of materials
Sorting
Stacking
Stamping and embossing
Clamping
Shifting
Positioning
ROBOT PNEUMATIK
CONVEYING
CONVEYING
CLAMPING
PUNCHING, BENDING & SOFA TESTING
MACHINING (DRILLING)
PACKAGING
ADVANTAGES
AND
DISADVANTAGES
OF COMPRESSED AIR
ADVANTAGES
AVAILABILITY
➤ Air is practically available everywhere
➤ It is available in unlimited quantities
➤ Air is clean no pollution

TRANSPORT
➤ Air can be easily transported in pipelines, even over long
distances
ADVANTAGES
STORAGE
➤ A compressor need not be in continuous operation
➤ Compressed air can be stored in a reservoir and removed as
required
➤ The reservoir can be transportable

TEMPERATURE
➤ Compressed air is relatively insensitive to temperature
fluctuations
➤ This ensures reliable operation, even under extreme
conditions
ADVANTAGES
EXPLOSION PROOF
➤ There is minimal risk of explosion or fire

CLEANLINESS
➤ Unlubricated exhaust air is clean
➤ Any unlubricated air does not cause contamination
➤ Useful in food, wood and textile industries
ADVANTAGES
COMPONENTS
➤ Operating components are of simple construction and
therefore relatively inexpensive

SPEED
➤ Compressed air is a very fast working medium
➤ High working speeds can be obtained

Others
➤ Air does not require backflow/tank
➤ Provide flexibility in machine control
DISADVANTAGES
PREPARATION
➤ Compressed air requires good preparation
➤ Dirt and condensate should not be present

COMPRESSIBLE
➤ It is not always possible to achieve uniform and constant
piston speeds with compressed air
DISADVANTAGES
FORCE REQUIREMENT
➤ Compressed air is economical only up to a certain force
requirement
➤ At 6-7 bar, and dependent on the travel and speed, the output
limit is between 20000 and 30000 Newton

NOISE LEVEL
➤ The exhaust air is loud
➤ The problem is largely solved with new silencers
DISADVANTAGES
COSTS
➤ Compressed air is a relatively expensive means of conveying
power
➤ The high energy costs are partially compensated by
inexpensive components and higher performance
UNITS
In a pneumatic system there are 2 main things that can be
controlled:
➤ Pressure (the force generated at the cylinder)
bar/pound per square inch (psi) /Pascal (Pa)
(1 bar = 14.5 psi = 105/100,000 Pa/100kPa)

➤ Flow rate (the speed of the cylinder)


COMPONENTS
OF A
PNEUMATIC
SYSTEM
PNEUMATIC SYSTEM BLOCK DIAGRAM
Air Service Control
Compressor Dryer Receiver Actuator
Unit Valve
➤ Air compressor – to raise the pressure of atmospheric air to higher
compressed air pressure

➤ Dryer – to dehydrate the compressed air before being piped


downstream so as to eliminate components from rust damage.

➤ Receiver – to store the compressed and dehydrated air

➤ Service Unit – regulator, filter unit and air lubricator

➤ Control Valve – to change the direction of compressed air

➤ Actuator – to convert the energy from compressed air into


mechanical energy
COMPRESSED AIR PREPARATION
COMPRESSED AIR SUPPLY
AIR
GENERATION
AND
DISTRIBUTION
`
COMPRESSOR
➤ Air is compressed using a compressor

➤ A motor is used to drawn air from the atmosphere before being


compressed by a compressor to obtain the pressure needed
Slide * *

*acting/piston
RECIPROCATING COMPRESSOR
➤ Use reciprocating/salingan motion of a piston to compress air

➤ Single stage and double stage compression

➤ Single stage compression produces lower pressure than


double stage compression
PISTON COMPRESSOR
➤ The piston compressor is widely used.
➤ Multi-stage compressors are required for compressing to high
pressure. The drawn in air is compressed by the first piston,
cooled and then compressed further by the next stage.
SELF READING
➤ JUN2017
➤ Single stage compressor use
only one cylinder
➤ Piston move downward while
air from atmosphere is suck
into cylinder chamber.
➤ During this Intake Valve open,
Discharge Valve closed
➤ Next air compressing process.
➤ Both valve is closed position.
➤ Then compressed air will be
discharged from cylinder
chamber through Discharge
Valve
DIAPHRAGM COMPRESSOR
➤ A diaphragm compressor is widely used in petrochemical and
food industries.
➤ Diaphragm compressor is usually used in transporting system
to generate pneumatics tools.
➤ Lubrication does not require in this type of compressors and
thus the final output pressure is free from any contamination.
➤ Diaphragm compressors are often selected when no
contamination is allowed in the output airline or atmosphere.
➤ Diaphragm compressors have limited output and
pressure, and they are most commonly used in light-duty
application.
ROTARY COMPRESSOR
➤ Use rotary motion to compress air
➤ There are four types:
• Lobe
• Screw
• Liquid ring
• Sliding vane
LOBE COMPRESSOR
ROTARY COMPRESSOR
SCREW COMPRESSOR
SLIDING VANE COMPRESSOR
COMPRESSOR ACCESSORIES
RECEIVER/PRESSURE TANK
RECEIVER/PRESSURE TANK
➤ Temporary storage for compressed air
➤ Stabilise the pressure of air feed
➤ Eliminate contaminant
➤ Cool down the compressed air, which was heated during
compression
➤ Helps in keeping cost low by engaging the compressor when
pressure level is low by means of a pressure switch
AIR
DRYERS
Air
dehydration

Continuous
Air dryer
cooler

Absorbance Adsorption Coolant Main line


Air cool Water cool
drying drying drying filter
Water produces:
➤ Hardening of Seals
➤ Corrosion
➤ Washing Out of Original Lubrication of Cylinders
➤ Swelling of Seals and Diaphragms

Therefore Air Dryers are Used to Reduce the Moisture


Content
AIR COOL
➤ Using air to blow off heat in the
compressed air.
So fan was used to blow out
the hot compressed air
The hot air will flow through the coil
WATER COOL
➤ Using water to cooled down
Compressed air
Air will flow through cooling coil
where the water will flow in and
out.
There are four types of air dryer:
➤ Refrigeration/Low Temperature Drying/Coolant drying
➤ Absorption
➤ Adsorption
➤ Main Line Filter
LOW TEMPERATURE DRYING / COOLANT /
REFRIGERATED DRYING
The lower the dew point the more the water will condense and
reduce the amount entrapped in the air. Using refrigeration
methods, it is possible to achieve dew points of between 2ºC
and 5ºC.

If compressed air is cooled down below dew point, condensation


ensure and water is precipitated
ABSORPTION ?
ADSORPTION ?
ABSORBANCE DRYING
➤ Medium – dehydrated chalk, magnesium chloride, lithium chloride

➤ Medium will change to liquid after absorb moisture

➤ Chemical high corrosive-must filter

➤ Simple installation of the equipment

➤ Low mechanical wear because there are no moving parts in the


dryer

➤ No external energy requirements

➤ High operating cost

➤ Need replace the medium/agent


ADSORPTION DRYING
➤ Silica or activated alumina
➤ The lowest dew point -90C
SELF READING
➤ Compressed air will enter the air dryer
through the first inlet
➤ Compressed air will flow into first column
(working) through the gel
➤ Water in the compressed air is deposited on
the surface of solids (gel). It is how water
vapor was being removed.
➤ some dry air from first column will flow into the
second column (regenerating) and some dry
air will flow out through the outlet
➤ The air from second column discharge
through exhaust
MAIN LINE FILTER
AIR TREATMENT
➤ Caused by
• Allergen
• Oil
• Moisture

➤ Problem
• wear the moving parts and seal
• Leakage
• Contaminated in food, pharmaceutical, chemical industry
FILTER
➤ The standard filter is a combined water separator and filter.

➤ If the air has not been de-hydrated beforehand, a considerable


quantity of water will be collected

➤ and the filter will hold back solid impurities such as dust and
rust particles
FILTER
➤ Standard filter
➤ Micro filter
➤ Sub-micro filter
STANDARD FILTER
MICRO FILTER
➤ The air flows from the
➤ inlet to the center of the
➤ filter cartridge then outwards
➤ through the outlet.
SUB-MICRO FILTER
➤ A sub-micro filter will remove virtually all oil and water and also
line particles down to 0.01 of a micron,

➤ Provide maximum protection for pneumatic precision


measuring devices, electrostatic spray painting, cleaning and
drying of electronic assemblies etc

➤ the principle of operation is the same as a micro filter, but its


filter element as additional layers with a higher filtration
efficiency
PRESSURE REGULATOR
➤ To provide constant air pressure
➤ To Provide a Constant Supply Pressure Irrespective of the
Pressure Fluctuations in the Main Line
➤ Constant Supply Pressure is essential for reliable and accurate
operation
➤ The following are related to the constant pressure
• Speed
• Force
• The time sequence of working elements
➤
FILTER-REGULATOR UNIT
➤ Air filtering and pressure regulation is combined in the
➤ Single filter regulator to provide a compact space saving unit
AIR LUBRICATOR
➤ For power components
➤ Cases
- Extremely rapid oscillating motions
- Cylinder large diameter
➤ To extend life cycle of pneumatic components

➤ To lubricate the component like DCV and cylinderThe Air


Lubricator is Used
• When Extremely Rapid Oscillating Motions are Required
• With Cylinders with Large Diameters ( 125mm diameter)
FILTER-REGULATOR-LUBRICANT
UNIT (FRL)/AIR SERVICE UNIT
AIR
SERVIC
E UNIT
➤ Air Service Unit is attached before working elements
➤ The Service Unit Consists of
• Air Filter
• Pressure Regulator
• Air Lubricator
• Pressure Gauge
ISO
SYMBOLS
DIRECTIONAL CONTROL VALVE
QUIZ
➤ Name it?

1 2

3 4

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