Automation Dialogue : Pneumatic Control Technology

OUTLINE :

I. PRINCIPLES OF PNEUMATICS
II. PNEUMATIC CONTROL SYSTEM
III. PNEUMATIC MAINTENANCE
 Air Service units and other Pneumatic equipment

Pressure boosters

Air preparation units

Vacuum generators
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Overview of vacuum components

VN VN-A,B,M VN-P VADMI OVEM

ESG Bernoulli VAD/VAK VAD-M-I

gripper OGGB

VAS(B) VAF ISV UOM UOMS VAM

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The DPA pressure amplifier

Pressure intensifier DPA-…

• Max. double supply pressure at the output
• Max. flow rate at the output
- DPA-40 300 l/min
- DPA-63 1000 l/min
- DPA-100 3000 l/min
New piston
• 2K piston with longer service life

Due to the use of especially high quality seals, the service

life of our pressure amplifiers is now longer than that of
most competitor products.
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Service unit series compared
Series MS series D series DB series,
polymer

Applications - From simple standard solutions to - Tried and tested a million times - Reliable and economical
Application-specific-Solutions in standard applications compressed air preparation

Breadth of range - Maximum breadth of range with - Concentration on all basic - Core functions: manual start-up
the latest functions functions of compressed air valve, pressure regulator, filter
- Integrated sensors for preventative preparation regulator, filter-regulator-lubricator
maintenance - Standard designs combination and distributor
- Certified exhaust valves for safety which can be ordered directly - Short delivery times: available as
requirements up to PL e from the catalogue stock item – tested and pre-
- From a complete individual module assembled
to an individually configurable
combination
Technology - Modular service unit in four sizes - Service unit with tie rod system - Series DB-MINI with port sizes 1/8“
- Optimum flow rates with minimum in four sizes and ¼“
size: from 1,000 l/min to 28,000 - Flow rate to 11,000 l/min. Light, sturdy polymer
l/min Flow rates up to 2,000 l/min
Fittings and Tubing
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QS fittings back

Design
• Sizes M3 … 1/2"
• Tube coupling Ø3 – Ø16
• Pressure range -0.95 … 10 bar,
temperature dependent up to 14 bar
• Temperature range -10 … 80°C
• Wide range of products

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QS-B fitting in new design back

Release ring
• Colour blue
• "B" marking Technical data QS/QSM QS-B/QSM-B
Compressed air, Compressed air,
Medium
vacuum vacuum
Temperature -10 … 80°C -10 … 60°C

Working pressure
-0.95 … 14 bar -0.95 … 10 bar
(temperature dependent)

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NPQP polypropylene fittings back

Range of applications
• Food and beverage industry
• Process industry
• Clean room
• Biotechnology/pharmaceuticals

Design
• Housing and thread: polypropylene
• Sealing material: EPDM
• FDA compliant / safe for use with food
• Lighter and cheaper than stainless steel
• Easy to attach and detach
• Resistant to acids and cleaning agents
• Corrosion resistance class 4
• Temperature range -20°C … +60°C
• Pressure range -0.95…10 bar

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Energy efficiency in pneumatic systems

Application

Compressed air
distribution
Compressed air
preparation
Compressed air
generation

A fully integrated approach is important!

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What is Pneumatics?

• Came from the Greek word “pneuma” meaning breath or wind.

• Branch of science which deals with the study of gases especially air. Its
properties and application at pressure higher (compressed) or lower (vacuum)
than atmospheric.
• It’s the industrial implementation and application of air powered actuators
(cylinders and air motors) and the control devices (valves) needed in their
operation.
Characteristics of Pneumatics

• Simple technology
• Flexible standard elements
• Easy to work with energy
• Air has unlimited availability
• Energy storable in any quantity
• Safe from explosion hazard
• Clean energy
• Suitable for low cost automation
Advantages of Pneumatic System

✓Availability. Air is available practically everywhere

✓Transport. Only needs pipelines even for long distances

✓Storage. Compressed air can be stored in air reservoir/tank

✓Temperature Insensitive. Relatively insensitive to temperature fluctuations

✓Explosion-Proof. Compressed air is non-combustible

✓Cleanliness. Air is clean

✓Speed. Air moves or diffuses fast

✓Overload-Safe. Components can be loaded even to the point of stopping

Disadvantages of Pneumatic System

✓ Preparation. Needs thorough preparation to filter dust, dirt and ensure constant
pressure

✓ Non-Uniform Speed. It is always not possible to achieve uniform speeds

✓ Non-Uniform Force and Torque. It is always not possible to achieve uniform force/torque

✓ Force Requirement. Used only for relatively small load (<50kN)

✓ Noise Level. Compressed Air is very noisy

Physical Fundamentals
Units of Pressure

Conversion of Units of Pressure

Bar kPa psi Rules of thumb

0.069 7 1
1 100 14,5 1 bar = 100 kPa = 14.5 (15) psi
(100 000 Pa)
2 200 29
3 300 43.5 1 Pa = 0.00001 bar = 0.000145 psi

4 400 58
5 500 72.5 1 psi = 0.069 bar = 6897.8 Pa

6 600 87
7 700 101
OUTLINE :

I. PRINCIPLES OF PNEUMATICS
II. PNEUMATIC CONTROL SYSTEM
III. PNEUMATIC MAINTENANCE
Pneumatic Structures

The elements in the system are

represented by symbols which
indicate the function of the
element.
Pneumatic Structures
Drive Components (Actuators)
Muscles of the system that do the actual work (such as lifting the workpiece, ejecting a
device, etc.)

In pneumatic systems, they convert fluid power (pneumatics) into mechanical energy.
Pneumatic Actuators

LINEAR CYLINDERS
➢ Single-Acting Cylinders
➢ Double-Acting Cylinders

ROTARY CYLINDERS
➢ Rotary Vane Cylinders
➢ Pneumatic Motors
Single-Acting Cylinders

Can perform linear work in one direction only, the other direction is performed via
spring.

Circuit Symbol :
Double-Acting Cylinders

Can perform linear work in both directions (forward stroke and return stroke).

Circuit Symbol :
Double-Acting Cylinders with End-Position Cushioning

Basically just a double acting cylinder which cushions (traps) air upon reaching the
forward and retract end position to reduce impact to base cap and bearing cap.

Circuit Symbol :
Rotary Vane Cylinder

Compressed air energy is directly converted to rotary motion via its construction.

Circuit Symbol :
Definition Related to Pneumatics

Force: Anything that causes an object with a mass to accelerate or decellerate. In

pneumatics, this is the mass that the piston has to move or the perpendicular force that is
applied to the tip of the piston rod.
Pressure: Is the force per unit area applied to an object, in pneumatics that is the pressure
of the compressed air.
Area: The area of an object where the force is applied, in pneumatics that is the area of the
piston or the area of the piston without the area of the rod.

PRESSURE
F=p*A

FORCE

AREA
NOW WHAT MAKES DRIVE COMPONENT WORK

In pneumatic circuit diagrams, the drive

components are always drawn at the top of
the diagram.

Compressed air must be applied to these

pneumatic actuators for them to function.

Special devices called energy supply are

required to generate and prepare compressed
air.
Energy Supply - Compressed Air Generation
Atmospheric Air

Energy Supply Compressor Vane, Screw, Piston

Electric Motor Storage Receiver

Diesel or Petrol Engine
Absorption,
Drying Refrigeration,
Adsorption

Distribution Air Distribution System

Filter, Regulator,
Service unit Lubricator

Plant
Types of Compressors
Reciprocating

Positive
Displacement
Rotary

Compressors

Centrifugal

Dynamic
Axial
Compressors

There are various type of compressors depending upon its design.

The most common are reciprocating compressors and screw compressors .

Circuit Symbol :
Air Preparation

AIR SERVICE UNIT

• Pressure gauge
• Pressure regulating valve
• Air filter
• Compressed air lubricator
Air Service Unit

Consists of an air filter, pressure regulating valve with pressure gauge and a
compressed air lubricator.

Air Filter - filters the compressed air of all impurities and any condensate it
contains.
Pressure Regulator - a reducing valve is assigned the duty of maintaining a
relatively constant operating pressure regardless of fluctuation and consumption
rate.
Compressed Air Lubricator - used to provide the pneumatic components with
sufficient lubrication. These lubricants inhibit the wearing of all moving parts, keep
frictional forces to a low level, and protect the equipment from corrosion.
Air Filter Inlet Outlet

Filter cleans the compressed air by

removing impurities:

1. dust
2. small particles
3. pipe scales
4. rust Baffles
5. water condensate
6. oil
Filter Element
Circuit Symbol:
Water Trap
w/o water drain w/ water drain
Drain
Filter Cartridges

Pre Filter cartridge Fine Filter cartridge Micro Filter cartridge Activated Carbon
5 1 0,01  Filter cartridge
40 
Pressure Regulator

Used to obtain uniform operating pressure for the pneumatic system in order to:

1. Obtain uniform speed

2. Obtain uniform force and torque

Circuit Symbol:
Lubricator

Air lubricator is used when:

1. Extremely rapid oscillating motions are required.

2. Cylinders with large diameters ( 125mm diameter).
3. Far distance between source and working elements.

Circuit Symbol:
Lubricator

Air flows through the lubricator from left to right. Some of the air flowing through
the valve is guided through a nozzle. Due to the resulting pressure drop, oil is
drawn from an oil reservoir through a feed pipe.
NOW WHAT CONTROLS DRIVE COMPONENTS

In pneumatic circuit diagrams, the drive

components are always drawn at the top of
the diagram.

If however energy supply is directly connected

to the drive components, cylinders would
permanently advanced and motors
permanently rotate.

This is why we need the so-called final control

element, a device that controls cylinder
motion.
Directional Control Valve

Directional control valves are devices which influence the path taken by an air
stream.
Valve Representation in Circuit Diagrams:

Squares represents the Represents unblocked

switching position flow of air

Represents spring actuate/ return Represents blocked flow

of air
Switching Symbols for Valves

The valve switching position is shown by a square.

The number of squares corresponds to the number of

switching position.

Lines indicate the flow paths, arrows indicate the direction of flow.

Closed ports are shown by two lines drawn at right angles to

one another.

The connecting lines for supply and exhaust air are drawn outside the
square.
Ports & Switching Positions
Some Common Directional Valves

Circuit Symbol:
Ports & Switching Positions
Ports & Switching Positions
Some Common Directional Valves

Circuit Symbol:

2/2 Way Valve 5/2 Way Valve

2 4 2

1
1 5 3

3/2 Way Valve 5/3 Way Valve

2 4 2

1
3 5 1 3
3/2 Way Valve

Provides one direction control of air stream usually used for single acting cylinder, wherein
one switching position vents the system while the other pressurizes the system.
5/2 Way Valve

Provides two-direction control of air stream usually used for double acting cylinder, wherein
one switching position pressurizes one working port and vents the other while the other
switching position does the opposite
HOW TO STOP CYLINDER OR VANE AT MID POSITIONS
5/3 Way Valve

Provides two-direction control of fluid stream just like 5/2 way valve but with a mid-position
which when actuated on both sides, blocks air flow (air is cushioned).
Methods of Actuation

Manual Actuation:
Methods of Actuation

Mechanical Actuation:
Methods of Actuation
Pneumatic Actuation:

Electrical Actuation:

Combine Actuation:
HOW TO CONTROL DRIVE COMPONENTS CHARACTERISTICS

Final control elements (directional control

valves) allows air stream to be controlled for
the proper activation of the drive components.

However, to control the characteristics of the

drive components operation such as speed of
extension of a cylinder, we need another type
of devices.

These are additional components that

modifies some characteristics of drive
components to obtain desired responses (eg.
slow extension speed, fast retraction)
Non-Return Valves

Valves that block the fluid flow in one direction and permit free flow in the other direction.
Type of Return Valves:
1.) Check Valves
• Used to allow fluid flow in only one direction; used as a bypass device.
2.) Shuttle Valves
• Used to combine two input fluid flow to one outflow wherein each inflows doesn’t
enter the other; used to perform logical-OR operation.
3.) Dual-Pressure Valves
• Used to combine two input fluid flow to one outflow performing logical-AND
operation.
Non-Return Valves

Check Valve / Non - return Dual-Pressure / AND Valve

Shuttle Valve / OR Valve

Terminator Connection

Blocked / Plugged

Open

Silenced
Application of Check Valves

Pneumatic
System

Bypassing PRV in flowBypassing contaminated Holding position Protection of pump

control regulator filter of cylinder from back-pressure
Shuttle Valves

A valve that perform logical-OR operation of two input fluid flow.

Circuit Symbol:

For example, a single acting

cylinder will only advance
when at least one of the
two manual-actuated valves
are triggered.
Dual Pressure Valves

A valve that perform logical-AND operation of two input fluid flow

Circuit Symbol

For example, a single acting

cylinder will only advance
when the two manual-
actuated valves are
simultaneously triggered.
Flow Control Valves

A valve that restricts or limits the flow of air thus reducing the flow rate.
Reducing the flow rate, reduces the pressure build up hence reducing speed of actuation of
drive components such as slow cylinder advancement or slow speed pneumatic motor
rotation.

Circuit Symbols:

Flow Control Valve, Flow Control Valve

Adjustable

One-Way Flow Control Valve, One-Way Flow Control Valve

Adjustable
Flow Control Valves

A. Flow Control Valve B. One-way Flow Control Valve

Two Kinds of Throttling

A. Exhaust Air Throttling

Piston is pneumatically cushioned between

supply air side and restricted exhaust air side
on the opposite side.

B. Supply Air Throttling

No air cushioning at the exhaust air side, only

at the supply air side.
Quick Exhaust Valves

A valve that allows full flow of air in one direction while directly exhausting air to
atmosphere in the other direction.
Directly exhausting air to the atmosphere without going through long exhaust lines or pipes
increases cylinder retraction or stoppage of motors.

Circuit Symbols:

Quick Exhaust Valve, w/

Silencer at Exhaust Port

Quick Exhaust Valve, w/o

Silencer at Exhaust Port
SUMMARY:
Controlling the speed of actuators is achieved by controlling the flow of air to or from the
actuators. NOT BY ADJUSTING THE PRESSURE

To reduce the speed of a cylinder

Single-acting: use one-way flow control valve to control the air going in to the
cylinder. (Supply air flow control).
Double-acting: use one-way flow control valve to control the air being pushed out of
the cylinder. (Exhaust air flow control). One flow control valve for each direction.

To increase the speed of a cylinder

Double-acting: use a quick exhaust valve to allow the exhaust air out of the
cylinder through as short a distance as possible. Use larger valves and tubing.
OUTLINE :

I. PRINCIPLES OF PNEUMATICS
II. PNEUMATIC CONTROL SYSTEM
III. PNEUMATIC MAINTENANCE
Routine Checking on Air Supply System

The first thing to check in any pneumatic machine is whether there is sufficient supply
of air for the machine, also make sure that all necessary electrical power is turned on.
Whether the system is simple or complex, maintaining the air supply is important for
proper working.
Poorly-prepared compressed air will eventually lead to malfunctions and may result in
the following tell-tale symptoms:

▪ rapid wear of seals, o-rings and moving parts in cylinder and valves
▪ oil built-up in valves
▪ contaminated silencers
▪ water condensates in air filter

Maintenance of air supply system can be divided into filter maintenance, pressure
regulator maintenance and lubricator maintenance.
Filter Maintenance

Water causes hardening of seals, corrosion and removing the original lubricant for
cylinders and valves. Oil and water may also cause seals to swell.

The selection of the correct filter is important in determining the quality and
performance of the pneumatic system. The amount of maintenance work for air filter
depends on the nature of the compressed air available and the number of components
fitted.

Maintenance work in this regard would include the following:

▪ Replacing and cleaning of the filter elements.

▪ Draining of the condensed water.
Pressure Regulator Maintenance

A constant pressure level is a must for a trouble-free operation of pneumatic control. In

order to provide a constant pressure condition, the regulator is fitted downstream filter.
Most regulators require very little maintenance but routine checks must be conducted to
ensure correct pressure settings.

▪ Normal pressure (6 bar) for cylinders and power valves

▪ Reduced pressure (3-4 bar) for control systems with numerous control valves
▪ Low pressure (less2.5 bar) for air sensor applications

When carrying out the pressure setting, it is important for safety reasons, that the
pressure reading on the pressure gauge in normal operation must not be greater than
2/3 of the maximum scale. A higher operating pressure would lead to energy wasteage,
whereas a lower operating pressure would lead to poor running of the machine.
Lubricator Maintenance

Compressed air lubricator has been part of the compressed air system for many
years. However, in recent years there are many concerns about the use of lubricators.
This has came about, after the problems encountered and experience and knowledge
gained.
Some of these are:
▪ malfunctions due to over lubricated components e.g. solenoid valves
▪ air pollution of working areas due to lubricated air
▪ gumming effects occurring after long plant shut-down

Nevertheless, lubrication of the compressed air by means of lubricators may be

necessary in cases where:
▪ cylinders need to move very fast i.e. to and fro.
▪ cylinders are of large diameters ( approx. 125mm and above)
Routine maintenance carried out on lubricators include:

▪ Checking the oil level

▪ ensuring the right type of oil is used e.g. light mineral oil and viscosity of SAE 10
▪ correct setting of lubricator

Oil should never be mixed with petrol. This is because petrol is a grease solvent and it
causes corrosion. It is better not to place any oil than allowing the wrong type of oil. It
does more damage to the pneumatic components.

The setting of the lubricator is normally done while the system is running. A value of
between 1 to 10 droplets per 1000 litres of air is used. An easier way is to place a piece of
white cardboard at a distance of about 2 cm from the exhaust port of the valve. The
silencer must be removed and the system is allowed to operate for about 100 cycles.
Examination of the cardboard will show the condition of the setting. It should be a faint
pale yellow colour on the cardboard. Dripping oil is a clear sign of over-lubrication.
General Preventive Maintenance for Pneumatic Systems
Daily:
Drain condensate from the filters if the air has a high water content and if no automatic
condensate drainage has been provided. With large reservoirs, a water separator with
automatic drain should be fitted as a general principle. Check the oil level in the
compressed-air lubricator, and check the setting of the oil metering.

Weekly:
Check signal generators for possible deposits of dirt or swart. Check the pressure gauge of
the pressure regulators . Check that the lubricator is functioning correctly.

Every 3 months:
Check the seals of the connectors for leaks. If necessary, re-lighten the connectors.
Replace lines connected to moving parts. Check the exhaust ports of the valves for leaks.
Clean filter cartridges with soapy water (do not use solvents), and blow them out with
compressed air in the reverse of the normal flow direction. Check the function of the
automatic exhaust valves.
General Preventive Maintenance for Pneumatic Systems
Every 6 months
Check the rod bearings in the cylinders for wear, and replace if necessary, also
replace the scraper and sealing rings.

Reduction of down time

Increase in productivity

Reduction of capital costs for stocks of

spare parts

Better deployment of
maintenance personnel
Benefits of
Reduction of
routine work
Planned Maintenance
Malfunctions and Failures
Malfunctions and failures may be caused by the following:

▪ Natural wear and tear of components and lines.

▪ Natural wear and tear is considerably accelerated by the effects of external
environmental influences and by the internal influences which, as far as
pneumatics is concerned, are generally connected with the condition of the
compressed air .
▪ Wear of units may lead to breakages , seizure of units, functional failures ,
leakages, etc.
▪ Contaminated air may lead to component failure caused by blockages, seizures
(oil) and increased wear (due to incorrect fitting)
▪ Lines may become blocked, split or bent, or may age prematurely due to
external influences.
Malfunctions, Failures and Remedy

Compressed-Air Filter and Regulator Valve

Types of malfunction Possible cause Remedy

Filter does not separate Filter fitted wrong way Fit and connect filter so
dirt and water round that flow is correct

Condensate level marked Drain condensate: if

line appropriate, fit automatic
condensate drain

Air discharges into the Regulator incorrectly fitted Fit regulator regularly
atmosphere at the as regards flow direction
pressure regulator
Malfunctions, Failures and Remedy

Lubricator

Types of malfunction Possible cause Remedy

Resination of lubricator Incorrect oil used Wash out lubricator

Lubricator does not Lubricator incorrectly Flow direction indicated

function correctly fitted by arrow

Too much oil in system Lubricator is incorrectly Adjust lubricator correctly

adjusted
Drain Off Oil
Oil is above mark

Oil level in lubricator falls The O-ring (t) is leaking Fit new O-ring
rapidly
Lubricator is adjusted Adjust lubricator correctly
incorrectly
Malfunctions, Failures and Remedy

Single-Acting cylinder

Types of malfunction Possible cause Remedy

When a power valve is Piston seal (1) is leaking, or is Renew the piston seat
connected, this blows at its loose on the piston rod
exhaust port
Piston rod (2) does not Pressure spring (3) or (3a) is Fit a new spring
return to the end position broken

Filter nipple(4) is clogged

Air blows into the Piston seal (1) is leaking, and Replace the sleeve and
atmosphere at the flanged flanged bush is damaged flanged bush
bearing bush
Piston seal (1) is fitted
upside-down Reposition the piston seal
Malfunctions, Failures and Remedy

Double-Acting Cylinder

Types of malfunction Possible cause Remedy

Air escapes at the piston rod Ring seal (2) is defective Fit a new ring seal
(1)
The power valve which is Piston seal (3) and piston (4) Replace both components
connected blows at port R are
Piston (4) travels hard in both Both cushioning rings (5) are Replace both cushioning rings
end positions worn out
Malfunctions, Failures and Remedy
Solenoid Valve

Types of malfunction Possible cause Remedy

Pilot spool does not The pilot piston (1) is Replace ring seal (2)
reverse jammed (contamination)

Coil does not respond Replace coil (3)

control lines do not open

Pressure insufficient for Check pressure level

Solenoid actuator is noisy Coil (3) heavily Clean coil
(humming) contaminated

Excessive play between Replace complete solenoid

armature (4) and armature actuator
tube (5)
Air flows out of armature Rubber seal in armature Replace armature
tube (5) (4) damaged

Nozzle (6) damaged Replace housing

Malfunctions, Failures and Remedy
Pneumatic Limit Valve

Types of malfunction Possible cause Remedy

Valve blows through the R The stem sealing washer Replace the washer
port when not actuated (1) is damaged

Ports P and A crossed Change the tubing over

over

Valve blows through the A Washer (1) or valve stem Replace the damaged
port (2) is defective components

Ports P and R crossed Change the tubing over

over
Valve blows at exhaust Diaphragm (3) is leaking Replace diaphragm
port in the diaphragm (3)

Valve does not reverse Pilot pressure too low Set pressure correctly

Pilot unit contaminated Check filter unit

Diaphragm (3) defective Observe minimum
pressure
Thank you very much for
your attention.