ME 434

Basic Hydraulic and Pneumatic Systems

By
Assoc. Prof. Hossam S.S. AbdelMeguid
Quiz : 3 Name: ID:
State True () or False ( X )
1. The volumetric capacity of a positive displacement pump is less than
that of a non-positive displacement pump.
2. Too low elevation head between the reservoir and the pump inlet
causes cavitation.
3. Efficiency is almost constant with the head in the case of non-positive
displacement pumps.
4. The sole purpose of pumps is to create pressure.
5. Mechanical efficiency indicates the amount of energy losses that occur
for reasons other than leakage.
Basic Pneumatic Systems
Contents
 Introduction  Sequential control

 Symbols  Sequence solution

 Circuit layout  5/3 Valves

 Actuator control 2/2 Valve  Poppet/spool logic

 Actuator control 3/2 Valve  Balanced spool logic

 Actuator control 5/2 Valve  Feedback

Click the section to advance directly to it

Case study A

• Consider a simple operation where a double-acting cylinder is

used to transfer parts from a magazine. The cylinder is to be
advanced either by operating a push button or by a foot pedal.
Once the cylinder is fully advanced, it is to be retracted to its
initial position. A 3/2-way roller lever valve is to be used to
detect the full extension of the cylinder. Design a pneumatic
circuit for the above-mentioned application.
Case study A
Components used
The pneumatic components which can be used to implement the
mentioned task are as follows:
 double acting cylinder
 3/2 push button valve
 3/2 roller valve
 shuttle valve
 3/2 foot pedal actuated valve
 5/2 pneumatic actuated direction control valve
 compressed air source and connecting piping
 Case study A
Working
 Upon actuation of either the push button
of valve (S1) or the foot pedal valve
(S2), a signal is generated at 1 or 1(3)
side of the shuttle valve.
 The OR condition is met and the signal
is passed to the control port 14 of the
direction control valve (V2).
 Due to this signal, the left position of
V2 is actuated and the flow of air starts.
 Pressure is applied on the piston side of
the cylinder (A) and the cylinder
extends.
 If the push button or pedal valve is
released, the signal at the direction
control valve (V2) port is reset.
 Case study A
Working
 Since DCV (V2) is a double pilot valve,
it has a memory function which doesn’t
allow switching of positions.
 As the piston reaches the rod end
position, the roller valve (S3) is
actuated and a signal is applied to port
12 of the DCV (V2).
 This causes actuation of right side of
DCV (V2).
 Due to this actuation, the flow enters at
the rod-end side of the cylinder, which
pushes the piston towards left and thus
the cylinder retracts.
Case study B

A plastic component is to be embossed by using a die which is

powered by a double acting cylinder. The return of the die is to
be effected when the cylinder rod has fully extended to the
embossing position and the preset pressure is reached. A roller
lever valve is to be used to confirm full extension. The signal
for retracting must only be generated when the piston rod has
reached the embossing position. The pressure in the piston
chamber is indicated by a pressure gauge.
Case study B
Components used
The pneumatic components to be used to implement this task are:
 double acting cylinder
 3/2 push button valve
 3/2 roller valve
 shuttle valve
 5/2 pneumatic actuated direction control valve
 pressure sequence valve
 compressed air source
 pressure gauge and connecting piping
 Case study B
Working
 When the push button valve (S1) is pressed,
the flow takes place through the valve and a
signal is sent to the control port 14 of the
direction control valve (V2).
 The left position of the direction control valve
(V2) is switched-on and the flow enters at the
piston-end of the cylinder (A).
 It causes the extension of the cylinder.
 Even if the push button is released the position
of the DCV (V2) will not change due to its
memory function.
 As the piston nears the end position, the roller
valve (S2) is actuated and pressure line is
connected to the pressure sequence valve (V1).
 During the embossing process the pressure at
the piston-side of the cylinder (A) increases.
 Case study B
Working
 This increase in pressure is indicated by the
pressure regulator (Z1).
 When the pressure reaches to its pre-set value
in the pressure sequence valve (V1), the 3/2
valve of pressure sequence valve switches and
the signal is applied to port 12 of the DCV
(V2).
 The right position of the DCV is actuated and
the piston retracts.
 During the retracting movement, the roller
valve (S2) is released and the signal at the
control port 12 of the DCV (V2) is reset and
the pressure sequence valve is also reset.
Case study C
Sequencing application
In process control applications such as sequencing, the
Pneumatics systems are generally employed. Electrical
components such as relays, programmable logic controllers are
used to control the operations of Pneumatic systems.
Case study C
Components used
The components used in the circuit are:
 double acting cylinder,
 3/2 roller lever valve,
 5/2 pilot operated direction control valve and
 3/2 push button valve.

By using this circuit, a continuous to and fro motion of the actuator is

obtained.
 Case study C
Working
 When the 3/2 push button is actuated, the
air flows from the source through the
push button valve to the 3/2 roller valve
(S1).
 The roller valve is already actuated by the
cylinder when the piston rod hits the
lever of S1.
 Therefore, there is continuous flow to the
5/2 pilot operated direction control valve
(DCV).
 The flow given to the pilot line 14
actuates the first position of DCV.
 The air flows from port 1-4 pushes the
piston head which causes the extension of
the cylinder.
 Case study C
Working
 As the cylinder fully extends it actuates
the 3/2 roller lever valve (S2).
 The roller valve is actuated and air flows
through the valve to the 5/2 DCV.
 The air enters the DCV through pilot port
12 actuating the second position.
 Hence the air flows from port 1-2 to the
actuator rod end, causing its retraction.
 The cylinder reciprocates till the supply is
stopped.
 In this way, we can achieve the
sequencing operation by controlled
actuation of various valves in a
pneumatic system.
Sequential control
 Circuit building blocks
a0 a1 b0 b1
A B

Run/End

• These circuits can be considered as building blocks for larger sequential circuits consisting
of two or more cylinders
• Each actuator will have a power valve and two associated feedback valves. The first
actuator to move also has a Run/End valve
Repeat pattern sequence
• A repeat pattern sequence is • The signal starting the first
one where the order of the movement must pass through
movements in the first half of the Run/End valve
the sequence is repeated in the • Needs only the basic building
second half blocks to solve
• Each actuator may have one Out • Examples of repeat pattern
and In stroke only in the sequences:
sequence
• A+ B+ C+ D+ A- B- C- D-
• There may be any number of
actuators in the sequence • A- B+ C- A+ B- C+
• C+ A+ B- C- A- B+
 Repeat pattern sequence
a0 a1 b0 b1
A B

Run/End

b0 b1 a1 a0

• The two cylinders A and B are to perform a simple repeat pattern sequence as follows:
A+ B+ A- B-
• Apply the rule “The signal given by the completion of each movement will initiate the next
movement”
• In this way the roller valves can be identified and labelled
 Repeat pattern sequence
a0 a1 b0 b1 c0 c1
A B C

Run/End

c0 c1 a1 a0 b1 b0

• For three cylinders A, B and C also to perform a simple repeat pattern sequence as
follows: A+ B+ C+ A- B- C-
• Apply the rule “The signal given by the completion of each movement will initiate the next
movement”
 Non-repeat pattern sequence
a0 a1 b0 b1
A B

Run/End

a0 b0 a1 b1

• If the rule applied to a repeat pattern sequence is applied to any other sequence there
will be opposed signals on one or more of the 5/2 valves preventing operation
• This circuit demonstrates the problem
• The sequence is A+ B+ B- A-
 Opposed signals
a0 a1 b0 b1
A B

Run/End

a0 b0 a1 b1

• When the valve is set to Run, cylinder A will not move because the 5/2 valve has an
opposed signal, it is still being signalled to hold position by the feedback valve b0
• If A was able to move + a similar problem will occur for the 5/2 valve of B once it was +
• The sequence is A+ B+ B- A-
 Mechanical solution
a0 a1 b0 b1
A B

Run/End

a0 b0 a1 b1

• The problem was caused by valves b0 and a1 being operated at the time the new
opposing instruction is given
• If these two valves were “one way trip” types and over tripped at the last movement of
stroke, only a pulse would be obtained instead of a continuous signal
Sequence solution methods
• The main solutions to solving • Shift register circuits are similar
sequences are: to cascade but use one logic
• Cascade (pneumatic) valve for every step
• Shift register (pneumatic) • Electro-pneumatic circuits use
• Electro-pneumatic solenoid valves and electro-
• PLC (Programmable logic mechanical relays
controller)
• PLC, the standard solution for
• Cascade circuits provide a medium to complex sequential
standard method of solving any systems (except where electrical
sequence. equipment cannot be used)
• It uses a minimum of additional
logic hardware (one logic valve
per group of sequential steps)
Cascade two group
• The A+ B+ B- A- circuit is solved • Because only one group output
by the two group cascade is available at a time it is not
method possible to have opposed signals
• The sequence is divided at the • A standard 5/2 double pressure
point where B immediately operated valve is the cascade
returns valve
• The two parts are allocated
groups l and ll Group l Group ll
• Gp l A+ B+ / Gp ll B- A- 4 2
• Two signal supplies are provided 14 12

from a 5/2 valve one is available Select l 5 1 3 Select ll

only in group l the other is
available only in group ll
Cascade (two group)
a0 a1 b0 b1
A B

b0
a1
Gp l
Gp ll

Sequence
Run/End
Gp l A+ B+ Gp ll B- A-

a0 b1
Cascade (two group)
a0 a1 b0 b1
A B

b0
a1
Gp l
Gp ll

Sequence
Run/End
Gp l A+ B+ Gp ll B- A-

a0 b1
Cascade (two group)
a0 a1 b0 b1
A B

b0
a1
Gp l
Gp ll

Sequence
Run/End
Gp l A+ B+ Gp ll B- A-

a0 b1
Cascade (two group)
a0 a1 b0 b1
A B

b0
a1
Gp l
Gp ll

Sequence
Run/End
Gp l A+ B+ Gp ll B- A-

a0 b1
Cascade (two group)
a0 a1 b0 b1
A B

b0
a1
Gp l
Gp ll

Sequence
Run/End
Gp l A+ B+ Gp ll B- A-

a0 b1
Cascade (two group)
a0 a1 b0 b1
A B

b0
a1
Gp l
Gp ll

Sequence
Run/End
Gp l A+ B+ Gp ll B- A-

a0 b1
 Cascade building blocks
• A two group building block
consists of a lever valve to run
and end the sequence plus the Gp l
5/2 double pilot operated
cascade valve 4 2 Gp ll
14 12
• For a two group system Run/En 5 1 3
consisting of any number of d Sel ll
2
cylinders this building block and 10
12
the cylinder building blocks are 3 1
all that is required to solve the Sel l
sequence
 Cascade building blocks
• This three group building Gp l
block establishes an
interconnecting pattern Run/End
that can be extended to
any number of groups Gp ll
Sel l
Sel ll

Gp lll

Sel lll
 Dual trip building blocks
• When a sequence has a cylinder Send A+

operating twice in one overall a1 in x

sequence a dual trip building
a1 in y
block may be required for each
of the two feedback valves
• The supply will be from A+ in A+ in
different groups and the output Group x Group y
go to different destinations
a1
• Example is for feedback valve a1
of cylinder A when A is sent +
both in Group x and Group y
Note: can often be rationalised to less
than these three components
Cascade rules
• Establish the correct sequence • Interconnect the blocks as
• Divide the sequence in to follows:
groups. Always start a sequence The first function in each group is
with the Run/End valve selecting signalled directly by that group
supply
group l e.g. The last trip valve operated in
R/E | A+ B+ | B- C+ | C- A- each group is supplied with main
• Select the cylinder building supply air and selects the next
blocks group
The remaining trip valves are
• Select the cascade building block supplied with air from their
• Select dual trip building blocks if respective groups and initiate the
next function
required
The “run/end” valve will control
the signal from the last trip valve
to be operated