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Introduction to Electro-Pneumatics Chapter

Definition

▪ is defined from the words of electro ELECTRO-PNEUMATIC

which means electrical and pneumatic which means
pressurized air. CONTROL
▪ The is an integration
of electrical and mechanical components with compressed air
source.
▪ is a pneumatic control system where air
pressure and direction of valve are controlled by an electrical
current. presented by: Dr. Minh-Tuan HO
minh-tuan.ho@hcmut.edu.vn
ME3001 – Hydraulic & Pneumatic Engineering 1

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Introduction to Electro-Pneumatics Outlines

Signal flow and components
of a Pneumatic control system

1. Introduction to Electro-Pneumatics

2. Basic Electrical Devices and Symbols

3. Design project

4. Cascade Method

5. Questions

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Introduction to Electro-Pneumatics Introduction to Electro-Pneumatics

Electrical signal control section Signal flow and components
of an Electro-Pneumatic control system

Solenoid valve

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Introduction to Electro-Pneumatics Introduction to Electro-Pneumatics

Advantages of using Electro-Pneumatics
Pneumatic power section
E-260
Electrical signal
input
(switch panel)
Push Button

1. Lesser wear-off parts. Lesser installation jobs.

i.e., Electrical control valve, Electrical switches
2. Replace tube in pneumatic system to electrical wire in electro-
pneumatic
3. Less parts are used → Reduce working space. Solenoid actuated Directional control valves form the
interface between the signal control section (electrical) and
4. Sensor and Controller (such as PLC) can be included in the
the pneumatic power section in an Electro-pneumatic system.
system
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Push Basic Electrical Devices

Seven basic electrical devices commonly used in the control of fluid
power systems are
1. Manually actuated push button switches
2. Mechanical Position Sensor (Limit switches)
3. Pressure switches
4. Solenoids
5. Relays
6. Timers
7. Temperature switches

Other devices used in electro pneumatics are

1. Proximity sensors
2. Reed switch
3. Electric counters

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Example : Input Element - Push Button Switch

Normally Open (NO) and Normally Close (NC)
In pneumatic circuit :
For example : 3/2-way Push button (valve)

Normally Open Normally Close

In electrical circuit :
For example : Push button switch
Push buttons are of two types
i) Momentary push button – nút nhấn thả/nhả/tạm thời (return to unactuated position
Normally Open Normally Close when release)
ii) Maintained contact or detent push button – nút nhấn (tự) giữ (has a latching
mechanism to hold it in the selected position)
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Proximity sensor Mechanical position sensor (limit switch)

(Pneumatic)
3/2-way N.C valve with roller (Limit switch)

(Electro-Pneumatic)
Mechanical Position sensor (Limit switch)

❑ Proximity sensor contain a transistor which conducts and

switches (trigger ON) when something comes near to the
sensors.
❑ Some of the proximity sensor only work with steel material
components － Inductive proximity sensor

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Proximity sensor Limit Switch

Any switch that is actuated due to the position of a fluid power component (usually a
piston rod or hydraulic motor shaft or the position of load) is termed as limit switch.

Proximity Sensor

There are two types classification of Limit switches depending upon method of
actuations of contacts
Question : a) Lever actuated contacts
b) Spring loaded contacts
1. Name the switch type used for START and STOP button.
2. What is the different between A1 and A2 in Electrical circuit? In lever type limit switches, the contacts are operated slowly. In spring type limit
switches, the contacts are operated rapidly.

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Relay
Contactor
E-140

Coil

When Toggle switch 1S3 is pressed, power is supplied to Relay K1 coil

which result to the all contactors in relay K1 change their state (open
→ close or close → open). Solenoid valve 1Y1 activate to ON

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N.O and N.C wire / cable connection

❑ Relay is an electrically actuated switch, contains a coil and a

contactor switch or multiples contactors.
❑ When power is applied to relay coil, the core magnetizes, drawing
the contact assembly in.
❑ This will change the state of all the contacts in the relay (i.e., N.O
contact becomes closed or N.C contact becomes open).
❑ Relay uses small amount of power to control switching (advantage).
The voltage applied to the coil doesn’t have to be the same as that in
control circuit.
Normally Close (N.C)
Example : Pin 21 22 ❑ Relay is used to allow low voltage control systems to switch large
current/ high voltage
Normally Open (N.O)
Example : Pin 41 44

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More about Relays

Animation (Relay OFF)
❑ Relay has a few functions as a safety device:
1. The high voltage output (i.e. 240V) can be switched ON
through a contactor using relay with low voltage (i.e. 24V)
supplied to a coil.
2. The high current output can be switched ON through a
contactor using relay with low current supplied to a coil.
3. Functioned as Safety control circuit for emergency power cut-
off (EMERGENCY START and STOP button) to the whole
circuit.

❑ Use in automation process → Switching more than one outputs

simultaneously using relay with a coil and multiple contactors.
❑ To control ON and OFF of various outputs sequences using several
Relay.
Source : UniKL Electro-Pneumatic Lecture Note, 2008

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Solenoid DCV
Animation (Relay ON)
❑ Solenoid valve is an electro-mechanical device that built-in
with a coil (solenoid) and a pneumatic Directional control
valve.
❑ Directional control valve (DCV) solenoid operated use
electrical signals to control pneumatic valves.
❑ They are used to start, to stop and/or to change the direction
of air flow.
❑ There are 2 types operated of directional control valve using
solenoid:
1. Directly operated valve
2. Pilot operated valve

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5/2 DCV single pilot operated single solenoid

with spring return 1. Directly operated valve
The cross section view of 5/2 way single solenoid in the normal and actuated Flow is releases to the consuming device via armature of the solenoid. In order to
positions are shown in Figure. In normal position, port 1 is connected to port obtain a sufficient cross section of opening, a comparably large armature is required.
2, port 4 is connected to port 5, and port 3 is blocked. When the rated voltage
This consequently requires a powerful return spring and the solenoid to generate a
is applied to coil 14, the valve is actuated through an internal pilot valve. In
actuated position, port 1 is connected to port 4 , port 2 is connected to port 3, high force. It is therefore of a large design with high power consumption.
and port 5 is blocked. The valve returns to the normal position when the
voltage to the armature coil is removed.

2. Pilot operated valve

The valve piston is moved via an air duct from pressure port 1. This only requires a
Low flow so that a comparatively small armature with minimal actuating force can
be used. A minimum supply pressure is required in order to actuate the piston
against the spring force. Solenoid can be configured in a small design and the
power consumption and heat emission is thus reduced.

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3/2 DCV single solenoid operated with spring

5/2 DCV double pilot operated double solenoid return

The cross section view of 5/2 way double solenoid in the normal and actuated
positions are shown in the Figure when the rated voltage is applied to coil 14, the The cross sectional view of 3/2 way single solenoid valve in the normal and
valve is actuated to a one switch in position with port 1 connected to port 4, port 2 actuated positions are shown in Figure. In the normal position, port 1 is blocked and
connected to port 3, and port 5 blocked. When the rated voltage is applied to the port 2 is connected to port 3 via back slot (details shown in the circle) When the
coil 12, the valve is actuated to the other switching position with port 1 connected rated voltage is applied to coil, armature is pulled towards the centre of the coil and
to port 2, port 4 connected to port 5 and port 3 blocked. in the process the armatures is lifted away from the valve seat. The compressed air
now flows from port 1 to port 2, and ports 3 is blocked. When the voltage to the coil
is removed, the valve returns to the normal position.

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Sample circuit Various solenoid/pilot actuated valves

3/2 DCV single solenoid with manual

override with spring return

3/2 DCV single pilot operated single

solenoid with manual override with
spring return

5/2 DCV single solenoid with single

manual override with spring return

5/2 DCV double solenoid with double

manual override with spring return

5/2 DCV double pilot operated double

solenoid with double manual override

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Symbol in Electrical circuit

Solenoid DCV

5/2-DCV double pilot operated

double solenoid

Solenoid
5/2-DCV Single pilot operated
single solenoid with spring
return

When Pushbutton switch SW1 is pressed, power is applied to Solenoid 3/2-DCV Single pilot operated
S1 which then change the electrical signal to pneumatic signal and single solenoid with spring
allow air flow to Left cylinder (single acting with spring return) for rod return
to extend.

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Direct control in electro-pneumatics Sample Circuit connection

Direct control is the control of an electro-pneumatic valve without using
intermediate components such as a relay, a contactor or an industrial
computer (PLC). The valve is connected directly to electric switch as shown
in Fig. below

Advantages of direct control

•Simple and easy
•Less wiring
•Cheap.

Disadvantages of direct control

•Remote control is not possible
•Switching more than one valve at a
time is not possible Red cable is a connection
•Latching is not possible from 24V line.
•Design improvement is not flexible.
Blue cable is a connection to
GND (0 V).

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Supply / Power component

Indirect control in electro pneumatics
Indirect control is the control of an electro-pneumatic valve using In Electro-Pneumatic system, the supply or power
intermediate components such as relays, contactors or programmable logic source component is divided into two, based on the
controllers (PLC). system component.
Advantages of indirect control systems 1. Pneumatic － Compressor
•Remote control is possible
•Switching more than one valve at a time is possible 2. Electrical －AC / DC power supply
•Latching is possible.
•Flexible design improvement and development. Symbol for 24V DC
•Incorporating logic operating conditions
(OR, AND conditions) IEC Standard JIC Standard

Disadvantages of direct control

•Complicated
•More wiring
•More cost involved

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Direct Control of Double Acting Cylinder Direct Control of Single Acting Cylinder
Forward stroke: The circuit is closed
when push button PB closes. A magnetic
field is produced in the coil Y. The armature
in the coil opens the passage for the
Forward stroke: The double acting compressed air. The compressed air flows
cylinder is controlled by 5/2 DCV. When from 1 to 2 of the 3/2 DCV to cylinder,
the pushbutton PB is pressed, coil Y is which travels to the final forward position.
energised and the directional control valve
is activated by compressed air via pilot
control. The piston travels to the final
forward position.

Return stroke: When the push button PB is released, the circuit is interrupted. The
magnetic field at coil Y collapses, the return spring of 5/2 becomes active and the Return stroke: When the push button PB is released, the circuit is interrupted. The
5/2 DCV switches back to its original position as shown in Figure 1.29. The magnetic field at coil Y collapses, the 3/2 way valve switches back to its original
position as shown in Figure 1.27. The compressed air in the cylinder then exhausts
compressed air in the cylinder then exhausts through port 5 of the 5/2 DCV and the
through port 3 of the DCV and the cylinder travel to the final rear position.
cylinder travel to the final rear position.

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Indirect Control of double acting cylinder Indirect Control of single acting cylinder
(using 5/2 way, single solenoid) Forward stroke: The circuit is closed
when push button PB closes. Closing
Forward stroke: The circuit is closed
of Push button PB energises a relay
when push button PB closes. Closing of
K1. The coil Y is energised via
Push button PB energises a relay K1.
normally open contact K1 (indirect
The coil Y is energised via normally
energising).
open contact K1 (indirect energising).
A magnetic field is produced in
A magnetic field is produced in
armature of the coil Y opens the
armature of the coil Y opens the
passage for the compressed air. The
passage for the compressed air through
compressed air flows from 1 to 2 of the
internal pilot. The compressed air flows
3/2 DCV to cylinder, which travels to
from 1 to 4 of the 5/2 DCV to cylinder,
the final forward position.
which travels to the final forward
position.

Return stroke: When the push button PB is released, the circuit is interrupted. Return stroke: When the push button PB is released, the circuit is interrupted.
Opening of Push button PB de-energises a relay K1. The magnetic field at coil Y is Opening of Push button PB de-energises a relay K1. The magnetic field at coil Y is
collapses due to the opening of contact K1 the 5/2 DCV switches back to its original collapses due to the opening of contact K1 the 3/2 way valve switches back to its
position as shown in Figure 1.30. The compressed air in the cylinder then exhausts original position as shown in Figure. The compressed air in the cylinder then
through port 5 of the DCV and the cylinder travel to the final rear position. exhausts through port 3 of the DCV and the cylinder travel to the final rear position.

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Control of Double Acting Cylinder AND Logic Indirect Control of double acting cylinder
(Serial connection of two contacts – AND circuit) (using 5/2 way, double solenoid)
Forward stroke: When push button
PB1 is pressed, coil Y1 is energised
Forward stroke: The piston of a double and 5/2 DCV changes over. The
acting cylinder is to travel out when both piston travels out and remains in the
the pushbutton switches are pressed. When final forward position until a signal is
pushbutton PB1 and PB2 are pressed, coil applied to coil Y2. The 5/2 DCV will
Y1 is energised. The 5/2 DCV switches over remain in the last position because it
and the piston travels to the final forward is double solenoid valve and has no
position. return spring.

Return stroke: When the push button PB1 is released and PB2 is pressed. Opening of
Push button PB1 de-energises a relay K1. The magnetic field at coil Y1 is collapses due
to the opening of contact K1. Closing of PB2 energises Y2 and the piston returns to its
Return stroke: When either one of the two pushbutton switch is released, the original position as a result of changeover of the 5/2 DCV. The 5/2 DCV will not switch
signal is removed from Y1 and the cylinder travels back to its original position. over if there is an active opposing signal. For example, if Y1 is switched on and a signal
is given to Y2, there will be no reaction as there would be an opposing signal.

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Latching circuits Control of Double Acting Cylinder OR Logic

Definition: It is a process where the relay contacts remain on (Parallel connection of two contacts – OR circuit)
without keeping the relay coil energized. In other words, it is
required somethings to keep the circuit powered for a certain Forward stroke: The piston of
function even though a pushbutton switch is released to the a double acting cylinder is to
open position travel out when either one of two
pushbutton switch is pressed.
When either pushbutton PB1 or
PB2 are pressed, coil Y1 is
energised. The 5/2 DCV
switches over and the piston
travels to the final forward
position.

Return stroke: When both the pushbutton switches are released, the signal is
removed from Y1 and the cylinder travels back to its original position.

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Latching Circuit with Dominant ON Latching Circuit with Dominant OFF

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Latching Circuit with Dominant ON Latching Circuit with Dominant OFF

When Start button (PB1) and Stop button (PB2) are pressed simultaneously, if the When Start button (PB1) and Stop button (PB2) are pressed simultaneously, if the circuit goes
circuit goes to ON position/relay coil is energised , then such a circuit is called to OFF position/relay coil is not energised , then such a circuit is called Dominant OFF
Dominant ON latching circuit. Refer to Figure, latching circuit. Refer to Figure,
a) When we press START push button PB1 is pressed and released , following a) When we press START push button PB1 is pressed and released , following operations
operations occurs: occurs:
1. Relay coil K1 in branch 1 ( vertical) is energised. All Contact K1 closes 1. Relay coil K1 in branch 1 ( vertical) is energised. All Contact K1 closes
2. Notice that there is a NO contact of K1 in branch 2 , which is connected parallel 2. Notice that there is a NO contact of K1 in branch 2 , which is connected parallel to PB1.
to PB1 and in series with PB2. This NO contact of K1 latches the start push This NO contact of K1 latches the start push button. Therefore even if the PB1 is
button. Therefore even if the PB1 is released, NO contact of K1 in branch 2 released, NO contact of K1 in branch 2 keeps coil K1 energised.
keeps coil K1 energised. 3. There is another NO contact in branch 3, which is connected to Y1. When push button
3. There is another NO contact in branch 3, which is connected to Y1. When push PB1 is pressed this also remain closed, as a result cylinder moves forward and remains
button PB1 is pressed this also remain closed, as a result cylinder moves there until stop button PB2 is pressed.
forward and remains there until stop button PB2 is pressed. b) When we press STOP push button PB2 is pressed momentarily and released , following
b) When we press STOP push button PB2 is pressed momentarily and released , operations occurs:
following operations occurs: 1. Relay coil K1 in branch 1 ( vertical) is de-energised. All Contact K1 opens
1. Relay coil K1 in branch 1 ( vertical) is de-energised. All Contact K1 opens 2. NO contact of K1 in branch 2 , which is connected parallel to PB1 is now open. This NO
2. NO contact of K1 in branch 2 , which is connected parallel to PB1 is now open. contact of K1 no more latches the start push button.
This NO contact of K1 no more latches the start push button. 3. NO contact in branch 3 is also open now, which is de-energises. As a result cylinder
3. NO contact in branch 3 is also open now, which is de-energises. As a result moves back to its home position and remains there until start button PB1 is pressed
cylinder moves back to its home position and remains in home position until again.
start button PB1 is pressed again.

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Oscillating motion of a double acting cylinder Direct Control of Automatic Return of a Double Acting Cylinder
(Forward )

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Oscillating motion of a double acting cylinder Indirect Control of Automatic Return of a Double Acting Cylinder
(Return ) (using double solenoid)

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Design project Design project

▪ The control system is implemented using double-acting cylinders and Sequence control with signal storage
5/2-way double solenoid valves. The pneumatic circuit diagram is by double solenoid valves
shown in Fig. 8.13. Application example: Feeding device

▪ The positional sketch of a feeding device is shown in Fig. 8.11. The

Pneumatic circuit diagram end positions of the two cylinders drives 1A and 2A are detected by
of the feeding device
the positive switching inductive proximity switches 1B1 and 2B2.
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Design project Design project

▪ A systematic approach should be used when designing the relay circuit diagram. It
makes sense to plan the circuit diagram for sensor evaluation and the "START"
pushbutton first. The individual steps in the sequence can then be added to the
diagram. The design stages are shown in Fig. 8.14.

Design of the
relay circuit diagram

Displacement-step diagram
of the feeding device

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Design project Design project

Sensor evaluation
Electrical circuit diagram with
sensor evaluation & first sequence step

▪ In a relay circuit the signals are combined with each other by the contacts of control
switches, pushbuttons and relays. The electronic proximity switches used here do
not have contacts; instead, they generate an output signal by means of an electronic
circuit. Each sensor output signal therefore acts on the coil of a relay, which in turn
switches the necessary contact or contacts (Fig. 8.15). If proximity switch 1B1 is
tripped, for example, current flows through the coil of relay K1. The related contacts
switch to the actuated position.
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Design project Design project

Second sequence step
First sequence step

The following preconditions must be satisfied before the sequence is

started:
▪ Piston rod of cylinder 1A in retracted end position (proximity switch
1B1 and relay K1 actuated)
▪ Piston rod of cylinder 2A in retracted end position (proximity switch
2B1 and relay K3 actuated)
▪ START pushbutton (S5) actuated
If all of these conditions are met, relay coil K6 is energised. Solenoid
coil 1Y1 is actuated, and the piston rod of cylinder 1A advances.
▪ When the piston rod of cylinder 1A reaches the forward end position, sensor 1B2
responds. The second step of the sequence is activated. Solenoid coil 2Y1 is
actuated, and the piston rod of drive 2A advances.
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Design project Design project

Electrical circuit diagram Third sequence step
of the feeding device

▪ When the piston rod of cylinder 2A reaches the forward end position, sensor 2B2
responds. The third step of the sequence is activated. Sole- noid coil 1Y2 is
actuated, and the piston rod of drive 1A retracts.
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Design project
References
Fourth sequence step
1. A. Esposito, Fluid power with applications, 7e, Pearson,
2014
2. P. Chapple, Principle of hydraulic systems design, 2e, ▪ When the piston rod of cylinder 1A reaches the retracted end
Momentum Press, 2015 position, sensor 1B1 responds. The fourth step of the sequence is
3. M.M. Abootorabi, Hydraulics & Pneumatics, Yazd activated. Solenoid coil 2Y2 is actuated, and the piston rod of drive
University 2A retracts.
▪ Fig. 8.19 shows the complete electrical circuit diagram of the feeding
device, including contact element tables and current path
designations.

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