Pneumatics

Circuit Design

Pneumatics System

Muhammad Redzuan Bin Che Noordin

POLITEKNIK UNGKU OMAR
 Movement for One Cylinder

Insert the Sub Title of Your Presentation

Design basic circuit for one cylinder based on:

a) Pneumatic circuit
• Direct Method
• Indirect Method

b) Electro-pneumatic circuit
• Direct Method
• Indirect Method
• Infographic Style

Movement for
One Cylinder

Direct Method inDirect Method

When a sensor is Need support from
activate, so the directed control valve
complete circuit can act before actuator is
and move. moving.

One Cylinder One Cylinder

Direct Method inDirect Method

OR
AND
Dual pressure valve: logic AND function
• The dual pressure valve has two inlets 1 and 1(3) and one
outlet 2.

• Compressed air flows through the valve only if signals are

applied to both inlets.

• One input signal at 1 or 1(3) blocks the flow due to the

differential forces at the piston slide.

• If signals are applied to both 1 and 1(3), the signal which is

last applied passes to the outlet.

• If the input signals are of different pressures, the larger of

the two pressures closes the valve and the smaller air
pressure is transferred to the outlet 2.

• The dual pressure valve is used mainly for interlocking

controls, safety controls, check functions and logic AND
operations.
Shuttle valve: logic OR function
• This non-return element has two inlets 1 and 1(3) and one
outlet 2.

• If compressed air is applied to the first inlet 1, the valve

seat seals the opposing inlet 1(3), the air flows from 1 to 2.

• Inlet 1 is closed, if air passes from 1(3) to 2.

• A signal is generated at the outlet.

• When the air flow is reversed, i.e. a cylinder or valve is

exhausted, the seat remains in its previously assumed
position because of the pressure conditions.

• This valve is also called an OR element.

• If a cylinder or control valve is to be actuated from two or

more positions, one or more shuttle valves should be used.
SETTING
CIRCUIT When drawing a complete circuit
DIAGRAM diagram, one should place the
pneumatic components on different
levels and positions, so the relations
between the components can be
expressed clearly. This is called the
setting of circuit diagrams. A circuit
diagram is usually divided into three
levels: power level, logic level and
signal input level.
BASIC RULES OF CIRCUIT DIAGRAM (1)
BASIC RULES OF CIRCUIT DIAGRAM (2)
BASIC RULES OF CIRCUIT DIAGRAM (3)
CASE STUDY
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.
MULTI ACTUATOR
CIRCUIT
MULTI ACTUATOR CIRCUIT
• Most of the practical pneumatic circuits use multi cylinders. They are operated in
specific sequence to carry out the desired task. For example, to drill a wooden
component first we need to clamp and then drill. We can only unclamp the
cylinder, if and only if the drill is withdrawn away from the workspace. Here
sequencing of movement of clamp cylinders and cylinder which carries the drill is
important. This sequencing is carried out by actuation of appropriate final control
valves like directional control valves. The position of the cylinders is sensed by
the sensors like limit switches, roller or cam operated valves.
MULTI ACTUATOR CIRCUIT
• Multi cylinder pneumatics circuits can be designed in various methods. There is
no universal circuit design method that suits all types of circuits. Some methods
are commonly used for compound circuits but would be too expensive for simple
circuits. There are five common methods used by engineering and they are given
below
1. Classic method
2. Cascade method
3. Step-counter method
4. Logic Design method (with Karnaugb-Veitch Maps)
5. Combinational circuit design
CLASSICAL
METHOD
• In classical method, circuit design is done by
use of general knowledge of pneumatics
following the sequence through intuitively. In
general, steps involves
o Write down sequence and draw motion
diagrams
o Draw in cylinders and control valves
o Complete circuits intuitively.
EXAMPLE
• Two cylinders are used to transfer parts from a
magazine onto a chute. When a push button is
pressed, the first cylinder extends. Pushing the
part from the magazine and positions it in
preparation for transfer by the second cylinder
onto the out feed chute. Once the part is
transferred, the first cylinder retracts, followed by
the second. Confirmation of all extended and
retracted positions are required.
SOLUTION
EXAMPLE 1
A+ B+ A- B-
 a1 b1 a0

A+ B+ A- B-

pb b0
 In majority of the pneumatic applications more
than one cylinder is used. The movement of
these cylinders are coordinated as per the
required sequence. Sensors are used for
confirming the cylinder position and the resultant
actuation of the final control element. Normally
limit switches are used. The activation of limit
switches of different cylinders will provide set or
reset signal to the final control valves for further
controlling the movement of various cylinders.
The limit switches have to be arranged in the
proper location with the help of motion diagram
MOTION DIAGRAM/
STEP DISPLACEMENT DIAGRAM
• In order to develop control circuitry for multi
cylinder applications, it is necessary to draw the
motion diagram to understand the sequence of
actuation of various signal input switches-limit
switches and sensors
• Motion diagram represents status of cylinder
position -whether extended(outstroke) or
retracted(instroke) in a particular step
A+ B+ B- A-
Motion of A+ represented by 1 to
TOTAL OF MOTION
2 from a0 to a1(going up) at
1 2 3 4 5 cylinder A.
a1
A Motion B+ represented by 2 to 3
from b0 to b1(going up) at cylinder
a0 B.

b1 Motion B- represented by 3 to 4
B from b1 to b0(going down) at
cylinder B.

b0 Motion A- represented by 4 to 5
from a1 to a0(going down) at
cylinder A.
ELIMINATING OF SIGNAL
CONFLICT
Various methods are used to solve problem of
signal conflicts in multi cylinder circuits.

• Idle return roller

• Reversing valve (memory valves)
• Modules as combination of valves

A+ B+ A- B- A+ B+ B- A- A+ A- B+ B-
SIGNAL CONFLICT
IDLE RETURN ROLLER

ROLLER LEVER LIMIT SWITCH IDLE -RETURN ROLLER LEVER LIMIT SWITCH

• Roller Lever type Limit Switch gives mechanical

signal which can be sensed in both direction
movement of piston rod cam
• Idle-Return Roller Lever Limit Switch gives
mechanical signal due to actuation of roller only in
one direction. This is conveniently used in Signal
Elimination
IDLE RETURN
ROLLER

• An idle-return roller
lever valve consists of a
3/2 DCV fitted with an
idle return roller
mechanism. The two
designs of the idle roller
is shown in
IDLE RETURN
ROLLER
• The idle return roller may be positioned in the control
system so that when the cylinder extends, the piston
passes over the idle – roller mechanism of the valve,
thus activating the valve. (Figure a ), but also permitting
the valve to be deactivated immediately when the piston
moves to the extreme end position (Figure b). As a
result, the valve generates a short output pulse during
the forward motion of the cylinder. The idle return
mechanism also allows the cylinder to retract without re-
activating the valve (Figure c and Figure d). Hence, in
the end position or during the return motion of the
piston, the valve does not gets actuated, and no output
signal is produced. For the generation of short output
pulse by the idle-return roller valve during the return
motion of the cylinder, this valve may be positioned in
the opposite direction as compared to the case during
the forward motion of the cylinder.
EXAMPLE
• 1A1+ 2A1 2A1- 1A1-
CASCADE CIRCUIT
• Cascade method is a simple procedure to create pneumatic circuits involving
many cylinders to generate a sequence of actions.
• Compare to basic circuit of multicylinder, cascade circuit has group/memory
valve and manifold line.
• The circuit is very popular used in drill machine as to control it step by step.
GENERAL CASCADE METHOD
1) The cylinder action sequence is listed.
2) The sequence is partitioned into groups, such that no letter is repeated in any
group. The aim is to minimize the number of groups.
3) If the last group has no letters in common with the first, it can be merged into
the first group.
4) Each cylinder is double acting.
5) Each cylinder is controlled by a 5/2 valve, actuated on both ends pneumatically
(pneumatic valve actuation lines are also called pilot lines).
GENERAL CASCADE METHOD (cont.)

6) Each cylinder is associated with two limit valves, one each at the + and –
positions.
7) Each group is assigned a manifold line. A manifold line is simply a tube with
multiple outlets. When the group is active, the manifold line associated with it is
pressurized. At all other times, it is open to the atmosphere. The manifold line
connects to the limit valves associated with the cylinders. This ensures that the
pilot valves (the 5/2 valves) never get contradictory signals (i.e both the pilot
lines of the valve are never at the same pressure.)
8) The air pressure in the manifolds is controlled by 5/2 valves called group
valves. The total number of group valves is one less than the total number of
groups.
EXAMPLE OF DESIGN
CASCADE
A+ B+ A- B-

• Divide the given circuits into groups. Grouping should be

done such that there is no signal conflict. Do not put A+
and A- in the same group. Similarly B+ and B- should not
be put in the same group. In other word A+ and A- should
belong to different group to avoid signal conflict.
• In the example of A+ B+ A- B- we can group as below

A+ B+ A- B-
Group 1 Group 2
EXAMPLE OF DESIGN CASCADE (cont.)

• Choose the number of group changing valve (memory valve) = no of groups – 1

In the example, we have 2 groups so we need one group changing valve.
Connect the group changing valve as follows. From the figure it is clear that when
the control signals I and II are applied to group changing valve, the air (power)
supply changes from Group 1(G1) to Group 2 (G2)
EXAMPLE OF DESIGN CASCADE
(cont.)
EXAMPLE OF DESIGN
CASCADE (cont.)

• Arrange the limit switch and

start button as given in the
lecture. (some tips will be
given)
• Draw the power circuit as
below:
• Draw the control circuit.
CASE STUDY

First cylinder A extends and

brings under stamping station
where cylinder B is located.
Cylinder B then extends and
stamps the job. Cylinder A can
return back only cylinder B
has retracted fully.
SOLUTION
 CIRCUIT
POSITION
DURING A+
ACTION
 CIRCUIT
POSITION
DURING
B+ ACTION
 CIRCUIT
POSITION
DURING B-
ACTION
 CIRCUIT
POSITION
DURING A-
ACTION
CONCLUSION

The cascade system provides a

straightforward method of
designing sequential circuits. It will
always give a workable circuit and
only rarely will it be possible to
suggest any improvements.