International Journal of Engineering Applied Sciences and Technology, 2019

Vol. 4, Issue 5, ISSN No. 2455-2143, Pages 478-485

Published Online September 2019 in IJEAST (http://www.ijeast.com)

SENSORS AND POSITION CONTROL METHODS

FOR PNEUMATIC SYSTEMS

Michail Papoutsidakis V.J. De Negri Avraam Chatzopoulos

Dept. of Industrial Design and Dept. of Mechanical Dept. of Industrial Design and
Production Engineering, Engineering, Production Engineering,
University of West Attica Federal University of University of West Attica
Athens, Greece Santa Catarina Athens, Greece
Brazil

Abstract—This research work contains information about higher pressure. Because of robustness and suitability in
modern controllers for pneumatic system and applications. hazardous places pneumatic controllers are often found in gas
To provide information in the most efficient way, ten pipeline industrial equipment. In comparison there is
different resources were examined and gained information possibility to use electric or electronic control system and they
is separated into two big parts: pneumatic controllers and can be less costly than pneumatic system if only few control
control methods; and pneumatic positioning systems. In components are needed.
the first part there is described different pneumatic Approachable components of pneumatic controllers involve
controllers and control methods for those systems also the sensing elements, bellows, relays, transducers, actuators,
same part includes information of comparing pneumatic flapper nozzle amplifier. Figure [1] is representing example of
controllers with digital controllers. The second part: simple pneumatic control system where the flow of water
pneumatic positioning systems examines two main groups through a pipe has kept constant at some established value.
of pneumatic positioning systems: open-loop and closed- Flow transducer measure actual water current. After that flow
loop. This part gets into deeper view of each group and rate is comparing with desired current. Difference between
gives information about smaller sections of each group. these values is called error. If there is error, the pneumatic
controller is sending signal to actuator which is pressing or
releasing valve until the required flow is reached.
I. INTRODUCTION
Pneumatics is type of engineering that uses gas or pressurized
air to achieve motion. Pneumatic systems are typically
powered by compressed air or compressed inert gases. A
controller is a device that collects an input signal from
measured process variable, compares this value with
predetermined one, and determines the appropriate amount of
output signal required by the final control element to provide
corrective action within a control loop. A pneumatic controller
is a mechanical device designed to measure temperature or
pressure and transmit a corrective air signal to the final control
element. In this work there will be provided information about
pneumatic systems controllers, control methods for pneumatic
systems and pneumatic positioning systems. Fig. 1. Pneumatic Control System
II. PNEUMATIC CONTROLLERS AND CONTROL METHODS
One of the general component of pneumatic control system is
Pneumatic controller is a mechanical device developed to the flapper nozzle amplifier or also can be called bleed- type
always keep in process variables, for example pressure, controller. This element can convert very small displacement
temperature, flow rate, fluid level, etc. Pneumatic controllers signal of change of air pressure. Figure [2] represents general
collect that kind of data and transmit penitentiary air signal to construction of flapper nozzle amplifier. The air supply
the final control element. Pneumatic controller are powered by constantly flows to one end of the pipeline which is making
compressed air or natural gas and in most cases pressure is permanence air pressure. At the same side there is orifice. At
from 15 to 20 psig, though in very large systems can be used

478
 International Journal of Engineering Applied Sciences and Technology, 2019
Vol. 4, Issue 5, ISSN No. 2455-2143, Pages 478-485
Published Online September 2019 in IJEAST (http://www.ijeast.com)

the other end of pipeline there is nozzle and a flapper. Gap overall arrangement of pneumatic proportional controller. The
between nozzle and flapper defines by the input signal. Air system consisting pneumatic components such as air relay,
flow through the nozzle depends on how close flapper is. flapper nozzle amplifier, bellows and springs.
When the flapper moves closer to the nozzle, the amount of air
which flows through the nozzle will decrease and air pressure
inside the pipe will increase. In other scenario, air pressure
will decrease if flapper recede from nozzle.

Fig. 4. Proportional Controller Elements

Fig. 2. Nozzle Flapper Amplifier Proportional controller acts in pneumatic system and making
output pressure and displacement proportional. Figure [5]
The main issue of flapper nozzle amplifier is limited air explains operating principle of similar proportional controller.
handling capacity. It cannot be useful unless air handling (A) In the moment when the control port is open, the exhaust
capacity is increased. To increase the volume of air to be valve which is between the control and exhaust chamber is
handle is using air relay. Figure [3] explains the principle of open. Thus, air in the control chamber equals to atmospheric
operation of an air relay. Air relay is directly connected to the pressure. Because of supply pressure, spring closes supply
supply line and the output pressure of flapper nozzle amplifier valve. (B) Pilot chamber pressure begins to rise, when sensing
(p2) is connected to lower chamber. Lower chamber is filled component moves closer to control port. When the pressure in
with diaphragm which movement causes output pressure (p2) pilot chamber reaches 3 psi, pressure overcomes the force of
amount. On top of diaphragm there is double-seated valve spring and closes the exhaust valve. (C) Because of increasing
which blocks air vent when the nozzle pressure increases, pilot pressure pilot diaphragm moves down and opens the
because flapper moves closer and pressure through nozzle supply port. Thus that makes supply air to freely pass to
decrease. On the other hand if more air goes through nozzle control line. (D) When the pressure increases in control
then output pressure (p2) decrease, the diaphragm moves chamber, then it acts against the control diaphragm to oppose
downwards and for that reason double-seated valve blocks air pilot pressure. After that when all of forces in every direction
supply line and connects output port to the vent. is equal, the supply valve is closed and the system is balanced.

Fig. 3. Air relay

Pneumatic controllers have different types. The simplest type

of controller is called proportional controller. Figure [4] shows

479
 International Journal of Engineering Applied Sciences and Technology, 2019
Vol. 4, Issue 5, ISSN No. 2455-2143, Pages 478-485
Published Online September 2019 in IJEAST (http://www.ijeast.com)

Fig. 6. Two-position Controller

Figure [7] describes operation of a two-position controller. (A)

In the moment when the control port is open, through the
supply hole flows air and it goes to supply chamber and out
the control chamber. Air pressure force spring to hold the
supply ball valve open and the exhaust valve closed. (B)
Because control port is closed, pressure in the pilot chamber
rises. In the moment when pilot pressure become greater than
opposing forces, the pilot diaphragm moves and presses the
supply ball valve. (C) Finally the pilot diaphragm opens the
exhaust ball valve, thus the air from control chamber is
released to atmosphere. This action decreases forces resisting
the pilot pressure and become a reason to fully open exhaust
valve and stay open until pilot pressure is reduced. After that
the actions sequence is reversed.

Fig. 5. Operation of Proportional Controller

Another quite similar pneumatic controller is called two-

position controller. Main differences between proportional and
two-position controllers are valve and spring arrangement.
Figure [6] demonstrates main part of two-position controller.

Fig. 7. Operation of Two-position Controller

480
 International Journal of Engineering Applied Sciences and Technology, 2019
Vol. 4, Issue 5, ISSN No. 2455-2143, Pages 478-485
Published Online September 2019 in IJEAST (http://www.ijeast.com)

A. Sensing elements in pneumatic controllers

There are three main sensing elements which are using in

sensor-controlled systems:
 Temperature sensing element
 Pressure sensing element
 Humidity sensing element
a) Temperature sensing element
There are various temperature sensing elements for example
bimetal elements, bellows, liquid, gas refrigerant filed bulb Fig. 9. Bourdon Tube
and capillary sensors. But one of the simplest is bimetal
element. That kind of element includes two strips of different c) Humidity sensing elements
metals. Those metals are combined together. Reason for two
dissimilar metal is that they expand in different temperature Mostly humidity sensing elements are made of hygroscopic
rates. When the temperature changes the metal bends. The materials. Those kind of materials act and hold water
bended metal position can vary the pressure of pneumatic molecules from surrounding environment and change size
controller. The most efficient to use one metal which has high when humidity is changed. Humidity sensing elements
coefficient of expansion, for example brass, and the another generally are made from two woods. The most commonly are
metal or alloy that has low expansion coefficient. Figure [8] used cedar and yew woods. The working principle is similar to
show how bimetal element works in the moment when is bimetal sensor instead of temperature changes it bends as
heated. humidity changes.

Main advantages of pneumatic controllers is:

 Safe to use in hazardous places
 Easy to maintain
 Low cost of installation
 Steady response
There is also some disadvantages:
 Leaking air
Fig. 8. Bimetal Sensor  Slow response
b) Pressure sensing elements  Hard to operate in subnormal temperatures.
Different pressure sensing elements can include diaphragms,
B. Digital and pneumatic control
bourdon tubes and bellows. In practice bourdon tubes used the
most. Figure [9] shows movement of bourdon tube sensor. The Because of disadvantages of pneumatic controllers and
sensor has flattened tube which is bent to circular form. One benefits of electronic controllers nowadays industry
end of the tube is connect to pressure source or vacuum and companies are choosing digital control. It is evident that
other end of tube is connected to some linkage, but can move digital controllers have capabilities for custom control logic
freely. When the pressure become higher, the tube tries to and communication also for process tuning. Another main
straight out and that kind of movement through linkage reason why companies are looking for digital controllers that
transfers motion to gear. Overall this sensor can indicate because pneumatic equipment prices have increased and main
position or actuate a controller. pneumatic suppliers decided to stop many product lines. But
on the other hand there are many companies that still using
pneumatic controllers in the gas pipeline industry. The main
reason why gas pipelines are still using pneumatic controllers
because there is always pressurized gas that runs the
controller, thus there is no need for additional power source.

481
 International Journal of Engineering Applied Sciences and Technology, 2019
Vol. 4, Issue 5, ISSN No. 2455-2143, Pages 478-485
Published Online September 2019 in IJEAST (http://www.ijeast.com)

Another reason that pneumatic controller unlike digital loop pneumatic positioning control is that open loop
controllers cannot be affected by lightning, thus it cannot start pneumatic positioning actuator contains hard mechanical
fire. stops. To get into deeper view of open loop system, it has two
covers in a pneumatic cylinder which makes hard mechanical
Table [I] compares most basic control functions between
stops that determine stop positions. Figure [10] demonstrates
pneumatic and digital controllers.
schematic view of such an actuator. This diagram shows air-
Table -1 cushioning mechanism which is provided by a piston (1,
Function Pneumatic Digital Figure [10]) with two cylindrical parts (2 and 3) which has
controller controller two cover cavities (4 and 5). According to the control
algorithm the solenoid control valve (6) connects the
Controlling Uses pressure Uses pressure
pneumatic cylinder to the supply pressure and exhaust port.
or flow, but or flow, and The maximum value of the piston velocity is defined by
changing can be adjustable throttles (7 and 8). A noncontact indication of
needs changed via cylinder piston position is provided by two permanent
hardware software magnets (9 and 10) included in the piston and two proximity
change sensors (11 and 12) attached to the outside of the cylinder
tube. Sensors indicate a cylinder position without contact.
Power source Pressurized External When the piston is moving from one side to another, the
air or gas electric switch closes by the magnetic field, this completes electrical
power circuit and produces an electrical signal.
Eligibility for Cannot be Requires
hazardous ignited additional
environment devices in
order to use
Robustness Cannot be Can loss
damaged by power or be
electrical damaged by
disturbances electrical
disturbances
Remote Impossible to Easy to access
access access unless
there is
electronic
Fig. 10. Block Diagram of the Pneumatic Cylinder with two
sensors Positioning Stops on the Ends
C. Summary
The main idea of the air cushioning is to reduce deceleration
Pneumatic controllers can be very useful in hazardous to a decent level. This is achieved when cushioning air absorb
environmental because they not require external electrical and dissipate the impact kinetic energy. Such working
power source and cannot be ignited. On the other hand principle can be seen in the pneumatic system if the piston
pneumatic controllers are old technology and nowadays more speed is above 0.2 m/s. Linear and radial moving of the
suitable are digital controllers because of benefits such as easy cushion seals has two main benefits of using it. First, it solve
control, remote access and etc. the misalignment problem. And the second big advantage of
using air cushioning is that it minimalizes the noise pollution
III. PNEUMATIC POSITIONING SYSTEMS which is harmful for workers and environment.
Pneumatic positioning systems are mostly found in robotic
and manipulator systems, welding and riveting machines, pick B. Controlling of neumatic actuator with two variable
and place devices, vehicles and etc. hard stops
Figure 11 demonstrate the pneumatic actuator with two
A. Open loop pneumatic positioning systems variable hard stops. It is used to stop the piston in the two
There are two main groups of pneumatic positioning variable position points within the whole piston stroke. The
controlling: open and closed loop positioning control. Usually structure and the working principle of this system is similar to
the main criteria which distinguishes open-loop and closed the one shown in Figure 10. The main difference is that to stop

482
 International Journal of Engineering Applied Sciences and Technology, 2019
Vol. 4, Issue 5, ISSN No. 2455-2143, Pages 478-485
Published Online September 2019 in IJEAST (http://www.ijeast.com)

piston is used shock absorbers instead of the air cushions. This

design provides piston speed in range from 2 to 3 m/s and
position stationarity in up to 0.01 mm. The main drawback of
such actuator is poor applicability because stopping points are
moved by hand, they are not programmable.

Fig. 12. Schematic Diagram of the Actuator with Multi-positioning

Cylinder

D. Closed loop pneumatic positioning systems

The other group of pneumatic positioning actuators is closed
Fig. 11. Schematic Diagram of the Pneumatic Positioning Actuator loop. This type of actuators have a transducer which measures
with two Variable Hard Stops and converts the actuator output signal to an electrical signal.
Then the command signal is compared with converted
To design shock absorber system there is necessary to evaluate feedback signal and the resulting error signal is sent to achieve
such criteria: the proper position. For closed loop pneumatic positioning
systems there is mainly used two types of technologies:
 The velocity of the cylinder airflow regulation using servo or proportional control valves
 The mass being moved and a braking mechanism.

 The external forces acting on the system E. Positioning system with servo or proportional control
 The system pressure valves
Figure 13 shows pneumatic positioning systems with direct
 The piston diameter acting proportional control of air pressure. This invention
includes control electronics with a range of standard
C. Pneumatic positioning system with multiposition pneumatic valves, cylinders and actuators. It uses direct acting
pneumatic cylinder proportional pressure regulators to continually check and
Another Pneumatic positioning systems uses multiposition adjust pneumatic pressure. This change is enough to ensure
pneumatic cylinder. This is open-loop system which usually precise control of cylinder positioning. The electro pneumatic
consists of two or three connected cylinders. Figure 12 positioning system has two proportional pressure regulators
demonstrate this type actuator with three pneumatic cylinders, one on either side of the pneumatic cylinder piston. On the one
which has four positioning points. The number of positioning side pressure regulator keeps a fixed pressure and on the other
points in this type of pneumatic positioning system is always side pressure is controlled by other proportional pressure
one more then there is connected pneumatic cylinders. Each regulator. The systems controller compares data of the
cylinder have the rod which is mechanical hard stop for the pressure sensors on both sides of cylinder and give command
sequential piston. For example in the case shown in Figure 12, signals to proportional pressure regulators. Using this simple
the two left pistons with their rods create the hard stop for the scheme piston are moved to that side where the pressure is
right piston. Although the design of the actuator is simple and lower.
provides high reliability, it has impacts during the stopping
which can disturb the fluent work of the positioning. Also in a
number of case, this type of system is massive because of the
big amount of the control solenoid valves.

483
 International Journal of Engineering Applied Sciences and Technology, 2019
Vol. 4, Issue 5, ISSN No. 2455-2143, Pages 478-485
Published Online September 2019 in IJEAST (http://www.ijeast.com)

predetermined point in case to reach the target position. Figure

14 demonstrate the schematic view of such a positioning
actuator.

Fig. 13. Electro Pneumatic Positioning System Schematic

Fig. 14. Positioning Actuator with Pneumatic Brake
Advantage of such kind method is increased accuracy. Effects
of piston slightly moving forward and backwards is eliminated 1 – Pneumatic cylinder
due to that fact that proportional pressure regulators constantly 2 – Mechanical brake
monitors the pressure. Also this kind of system can control 3 – Pneumatic cylinder which drives mechanical brake
pressure within very narrow range that means that if actuators 4 – Positioning sensor
are chosen correctly and tuning of the controller is optimized 5 – Valve controlling the pneumatic brake cylinder
the system can reach ±1 mm positioning accuracy. V1 – V4 – Load displacement valves
To achieve high speed and accurate actuator movement valve R1 – R4 – Throttles
should quickly and responsibly act to commands from the
control system. When the pneumatic cylinder reaches the Pneumatic cylinder is controlled by four valves which are
desired position, the valve shifts over center according to the arranged in pair series. It allows to achieve independent
internal algorithms to build up pressure for smooth adjustment of high speed xm and low speed xc of the load.
deceleration to the set point with the necessary dynamic Four throttles perform those adjustments. The positioning
characteristics. process has two stages. At the first stage, the load speed is
The biggest role in the positioning servo pneumatics working reduced by pneumatic means and at the second stage the
process play the control algorithms. In this closed loop system, mechanical brake is applied to the rod and it holds the load to
acceleration and velocity are controlled using three loop the desired position. Figure 15 demonstrate an usual velocity
position feedback. The controller adds three signals which curve for this positioning process and the control algorithm for
include: cylinder position gained directly from the position this actuator, which is demonstrated in Table II. Here, load
sensor, velocity and acceleration derived from position vector position – x; velocity – ẋ; Vi determines the valve`s state (i is
and from those three different signals it generates the valve number: 1 – valve is energized, solenoid action; 0 –
correction signal to the valve. valve is deenergized, spring action); coordinate of the
A practical point of view is that any servo system must be positioning point – xd; x1 is the distance from the positioning
tuned. In this case, to achieve stable operation control system point where the cylinder starts to change the velocity from ẋm
evaluates baseline loop characteristics such as control valve, to ẋc; and x2 is the distance from the positioning point where
cylinder, payload and motion parameters. Also to optimize the brake is switched on.
performance the adaptive control algorithms evaluate the
quality of motion after every cycle. So system is capable to
adapt to payload changes or seal and bearing characteristics
change with use.
F. Pneumatic positioning system with braking mechanism
Other technology in closed loop positioning system is
braking mechanism. This type of actuator usually uses a
pneumatically driven external mechanical brake with spring
loaded friction pads which acts typically on the rod of the
pneumatic actuator. Usually the brake is activated by
increased air pressure. In pneumatic braking systems
positioning is achieved by applying the pneumatic brakes at a Fig. 15. Velocity Changing Curve

484
 International Journal of Engineering Applied Sciences and Technology, 2019
Vol. 4, Issue 5, ISSN No. 2455-2143, Pages 478-485
Published Online September 2019 in IJEAST (http://www.ijeast.com)

Table II. Control algorithm the tolerance band (Δ). When position x is within Δ the logic
commands for magnetorheological braking is given in step
wise or progressive braking. To provide an estimation of
system velocity the position is differentiated. System velocity
is the main criteria for an error function that passes through a
controller. This signal is summed with the magnetorheological
braking signal to provide constant velocity control.

Pressure variation, brake-pad wear, variation of the brake H. Summary

switching time, and the friction force in the pneumatic
cylinder makes system tuning to work. Typically, the x1 value Pneumatic positioning systems are based on two main groups.
remains the same in all working process, it is not depending of Open and closed loop. Open loop systems are quite simple and
any variation in the actuator operating conditions. The nature usable if only there is needed a few constant stopping points,
of the transitional process is the main criterion in x1 value but they are poorly adaptive if there is needed to change a
selection to achieve insignificant low speed xc variation stopping positions. Closed loop systems are more adaptive to
before approaching the position x. To compensate the such changes. It also evaluate changes which appear during
influence of variation in operation conditions of the actuator the systems use, so it can provide more accurate moving and
the x2 value is changed. stopping positions.
G. Pneumatic positioning system with magnetorheological IV. ACKNOWLEDGMENTS
braking device
Another positioning actuator uses magnetorheological braking
All authors would like to thank the University of West Attica
devices placed in parallel with pneumatic cylinder.
for the financial support provided to them for this research
Magnetorheological braking devices is based on
project.
magnetorheological fluids which has ability to reversibly
change from free flowing liquid to a semisolid with V. REFERENCES
controllable yield strength in milliseconds when magnetic
field is applied.
Magnetorheological brakes according to the applied current [1] R. W Haines, D. C Hittle “Control Systems for Heating,
proportionally creates a braking force. Accurate and robust Ventilating and Air Conditioning” Springer, pp. 366,
motion control is achieved through closed loop feedback of 2003.
the positioning sensor. Figure 16 demonstrate the schematic [2] I. L. Krivts, G. V. Krenjnin “Pneumatic Actuating
diagram of such a positioning actuator. To guarantee that the Systems for Automatic Equipment” Taylor & Francis
cylinder is directed toward the desired position the three Group, LLC, pp. 335, 2006.
position solenoid control valve takes action. The [3] B. Dehgham „Position Control of a Pneumatic System
magnetorheological brake is capable enough to stop the Using Adaptive Intelligent Methods“ Queen`s University,
pneumatic cylinder. This gives the full control with the ability pp. 160, June 2012.
to adjust a broad dynamic range of velocity control. [4] D. Waller, H. Werner „Pneumatics Workbook Basic
Level“ Festo Didactic GmbH & CO, pp 194, 2002.
[5] K. E Rydberg “Basic Theory for Pneumatic System
Design” Linkoping university, pp. 34, 1997.
[6] N. Franklin “Basic Pneumatics” Rev. 0100, pp 120, 1997.
[7] P. Croser, F. Ebel “Pneumatics Basic Level”, Denkendorf,
pp 51, 2002.
[8] S. Vincent, J. Bridges, “Positioning with air”, 2015.
[9] NPTEL, “Mechatronics and Manufacturing Automation,
2014.
Fig. 16. [10] C. Wilson, “Digital vs Pneumatic Control”, 20014.
Positioning Actuator with Magnetorheological Brake

Pneumatic control algorithm logic is simple Boolean logic

based on the sign of the position error. According to this logic
the valve stay to its neutral position when position x is within

485