COURSE NUMBER: ME 433

Fluidics
 
Pneumatic system & circuit

Course teacher
 Prof. Mahbubur Razzaque

1
 PNEUMATIC SYSTEM

Pneumatic systems use pressurized gases to transmit and control power. As the
name implies, pneumatic systems typically use air (rather than some other gas)
as air is a safe, low cost and readily available fluid. It is particularly safe in
environments where an electrical spark could ignite leaks from system
components.
 
There are several reasons for considering the use of pneumatic systems instead
of hydraulic systems. Liquids exhibit greater inertia than do gases. In hydraulic
systems the weight of oil is a potential problem when accelerating and
decelerating actuators and when suddenly opening and closing valves.

Liquids also exhibit greater viscosity than do gases. This results in larger
frictional pressure and power losses. Also, since hydraulic systems use a fluid
foreign to the atmosphere, they require special reservoirs and no-leak system
designs.

Pneumatic systems use air that is exhausted directly back into the surrounding
environment. Generally speaking, pneumatic system are less expensive than
hydraulic systems.

2
However, because of the compressibility of air, it is impossible to obtain precise,
controlled actuator velocities with pneumatic systems. Also, precise positioning
control is difficult. In applications where actuator travel is to be smooth and
steady against a variable load, the air exhaust from the actuator is normally
metered.

Whereas pneumatic pressure are quite low due to explosion dangers involved if
components such as air tanks should rupture (less than 250 psi), hydraulic
pressures can be as high as 12000 psi. Thus, hydraulics can be high-power
systems, whereas pneumatics are confined to low-power applications. Industrial
applications of pneumatic systems are growing at a rapid pace. Typical examples
include stamping, drilling, hoisting, punching, clamping, assembling, riveting,
materials handling, and logic controlling operations.

In pneumatic systems, compressors are used to compress and supply the

necessary quantities of air. Compressors are typically of the piston, vane, or
screw type. Basically, a compressor increases the pressure of a gas by reducing
its volume.

Pneumatic systems normally use a large centralized compressor, which is

considered to be an infinite air source similar to an electrical system where you
merely plug into an electrical outlet for electricity.
3
In this way, pressurized air can be piped from one source to various locations
throughout an entire industrial plant. The compressed air is piped to each
circuit through an air filter to remove the contaminants, which might harm the
closely fitting parts of pneumatic components such as valves and cylinders.

The air then flows through a pressure regulator, which reduces the pressure to
the desired level for the particular circuit application. Because air is not a good
lubricant, pneumatic systems require very fine mist of oil into the air
discharging from the pressure regulator. This prevents wear of the closely fitting
moving parts of pneumatic components.

Free air from the atmosphere contains varying amounts of moisture. This
moisture can be harmful in that it can wash away lubricants and thus cause
excessive wear and corrosion. Hence, in some applications air dryers are needed
to remove the undesirable moisture.

Since pneumatic systems exhaust directly to atmosphere, they generate

excessive noise. Therefore, mufflers are mounted on exhaust ports of air valves
and actuators to reduce noise and prevent operating personnel from possible
injury resulting not only from exposure to noise but also from the high speeed
airborne particles.

4
PROPERTIES OF AIR
 
Air is actually a mixture of gases containing about 21% oxygen, 78% nitrogen,
and 1% other gases such as argon and carbon dioxide. The preceding
percentage values are based on volume. Air also contains up to 4% water vapor
depending on the humidity. The percent of water vapor in atmospheric air can
vary constantly from hour to hour even at the same location.

The earth is surrounded by a blanket of air-the atmosphere. Because air has

weight, the atmosphere exerts a pressure at any point due to the column of air
above that point. The reference point is sea level, where the atmosphere exerts a
pressure of 14.7 psia (101 kPa abs).

When making pneumatic circuit calculations, atmospheric pressure of 14.7 psia

is used as standard. The corresponding standard specific weight for air is 0.0752
lb/ft3 at 14.7 psia and 68 oF (11.8 N/m3 at 101 kPa abs and 20 oC).

Free air is considered to be air at actual atmospheric condition. Since

atmospheric pressure and temperature vary from day to day, the characteristics
of free air vary accordingly. Thus, when making pneumatic circuit calculations,
the term standard air is used. Standard air is sea level air having a
temperature of 68 oF, a pressure of 14.7 psia (101 kPa abs and 20 oC)and a
relative humidity of 36%.
5
COMPRESSOR
 
A compressor is a machine that compresses air or another type of gas from a
low inlet pressure (usually atmospheric) to a higher desired pressure level. This
is accomplished by reducing the volume of the gas. Air compressors are
generally positive displacement units and are either of the reciprocating
piston type or the rotary screw or rotary vane types.

Compressor Starting and Unloader Control

 
An air compressor must start, run, deliver air to the system as needed, stop, and
be ready to start again without the attention of an operator. Since these
functions usually take place after a compressed air system has been brought up
to pressure, automatic controls are required to work against the air pressure
already established by the compressor.

If an air compressor is started for the very first time, there is no need for a
starting unloader control since there is not yet an established pressure against
which the compressor must start. However, once a pressure has been
established in the compressed air piping, a starting unloader is needed to
prevent the established air pressure from pushing back against the compressor,
preventing it from coming up to speed.

6
Pressure-switch-type unloader control: When the pressure switch shuts the
electric motor off, pressure between the compressor head and the check valve is
bled off to the atmosphere through a release valve. The compressor is then free
to start again whenever needed.

Centrifugal-type unloader control: To provide a greater degree of protection

for motors and drives, an unloader valve operates by the air compressor itself
rather than by the switch. This type is preferred on larger compressors. A totally
enclosed centrifugal unloader operated by and installed on the compressor
crankshaft is best for this purpose.

Once an air compressor is equipped with a starting unloader, it may be operated

automatically. Normal air compressor operation calls for 50 to 80% running
time when using pressure switch controls. 

An air compressor that cycles too often (more than once each 6 min) or one that
runs more than 80% of the time delivering air to the tank should be regulated
by a constant-speed control.

7
Example 13-12: A single acting pneumatic cylinder with a 1.75 inch piston dia
and 6 inch stroke drives a power tool using 100 psig air at 80 deg F. If the
cylinder reciprocates at 30 cycles/min, determine the air consumption rate in
scfm (cfm of air at standard atmospheric conditions of 14.7 psia and 68 deg F).

Solution:
The volume per min of 100 psig cylinder,
Q2 (ft3/min) = displacement volume (ft3) x reciprocation rate (cycles/min)
= piston area (ft2) x piston stroke (ft) x reciprocation rate (cycles/min)
= p/4 x (1.75/12)2 x (6/12) x 30 = 251 ft3/min
Volume per min of air (scfm) consumed by the cylinder,

Q1 = Q2 (p2/p1)x(T1/T2)

Where, p2 = 100 + 1.7 = 114.7 psia

p1 = patm = 14.7 psia
T2 = 80 + 460 = 540 deg R
T1 = 68 + 460 = 528 deg R

Using these data, Q1 = 0.0251 x(114.7/14.7)x(528/540) = 1.91 scfm. If the

temperature change is ignored, Q1 = 0.0251 x(114.7/14.7)x(528/528) = 1.96
scfm. The error is only 2%. However, if the temperature change is high, the error
may not be ignored. 8
Example 13-13: For the pneumatic cylinder driven power tool of example 13-
12 at what rate can reciprocation take place? Use the following data.
piston diameter = 44.5 mm
piston stroke = 152 mm
air pressure and temperature (at the pneumatic cylinder) = 687 kPa gage
and 27 deg C
Available flow rate = 0.0555 standard m3/min (cfm of air at standard
atmospheric condition of 101 kPa abs and 20 deg C.

Solution:
The volume per min of air consumed by the cylinder,
Q2 = Q1 (p1/p2)x(T2/T1)

Where, p2 = 687 + 101 = 788 kPa abs

p1 = patm = 101 kPa abs
T2 = 27 + 273 = 300 K
T1 = 20 + 273 = 293 K
Using these data, Q2 = 0.0555 x(101/788)x(300/293) = 0.00728 m3/min.

Now, Q2 (m3/min) = displacement volume (m3) x reciprocation rate (cycles/min)

= piston area (m2) x stroke (m) x reciprocation rate (cycles/min)
= p/4 x (0.0445)2 x 0.152 x recip. rate (cycles/min) = 0.00728 m3/min
Solving, reciprocation rate = 30 cycles/min
9
 BASIC PNEUMATIC CIRCUITS

Pneumatic circuits are similar to their hydraulic counterparts. One

difference is that no return lines are used in pneumatic circuits because the
exhausted air is released directly into the atmosphere. This is depicted by a
short dashed line leading from the exhaust port of each valve.

Also, no input device (such as a pump in a hydraulic circuit) is shown,

because most pneumatic circuits use a centralized compressor as their
source of energy. The input to the circuit is located at some conveniently
located manifold, which leads directly into the filter-regulator-lubricator
(FRL) unit.

Figure 14-5 shows a simple

Operation of Single-Acting Cylinder
pneumatic circuit, which
consists of a three-way valve
controlling a single-acting
cylinder. The return stroke is
accomplished by a spring
located at the rod end of the
cylinder.
10
When the push-button valve is actuated, the cylinder extends. It retracts
when the valve is deactivated. Needle valves V1 and V2 permit speed
control of the cylinder extension and retraction strokes, respectively.

Operation of Double-Acting Cylinder

Figure 14-6 shows the directional control of a double-acting cylinder using

a four-way valve. Note that control of a double-acting cylinder requires a
DCV with four different functioning ports (each of the two exhaust ports
perform the same function). Thus, a four-way valve has four different
functioning ports. In contrast, the control of a single-acting, spring-return
cylinder requires a DCV with only three ports. Hence a three-way valve has
only three ports. Actuation of the push-button valve extends the cylinder.
The spring offset mode causes the cylinder to retract under air power.
11
Air Pilot Control of Double-Acting Cylinder

In Figure 74-7 we see a circuit in which a double-acting cylinder can be

remotely operated through the use of an air pilot-actuated DCV. Push-button
valves V1 and V2 are used to direct airflow (at low pressure such as 10 psi)
to actuate the air-piloted DCV which directs air at high pressure such as 100
psi to the cylinder. Thus, operating personnel can use low-pressure push-
button valves to remotely control the operation of a cylinder that requires
high-pressure air for performing its intended function. When V1 is actuated
and V2 is in its spring offset mode, the cylinder extends. Deactivating V1
and then actuating V2 retracts the cylinder.
12
Cylinder Cycle Timing System

Figure 14-8 shows a circuit that employs a limit valve to provide a timed
cylinder extend and retract cycle. When push-button valve V3 is
momentarily actuated, valve V2 shifts to extend the cylinder. When the
piston rod cam actuates limit valve V4, it shifts V2 into its opposite mode to
retract the cylinder. Flow control valve V1 controls the flow-rate and thus
the cylinder speed.

13
Two-Step Speed Control System

A two-step speed control system is shown in Figure 14-9. The operation is

as follows, assuming that flow control valve V3 is adjusted to allow a
greater flow-rate than valve V4. Initially the cylinder is fully retracted.
When push-button valve V1 is actuated, airflow goes through valves V2,
V3, and the shuttle valve V5 to extend the cylinder at high speed. When the
piston rod cam actuates valve V6, valve V2 shifts. The flow is therefore
diverted to valve V4 and through the shuttle valve.

However, due to the low

flow setting of valve V4, the
extension speed of the
cylinder is reduced. After the
cylinder has fully extended,
valve V1 is released by the
operator to cause retraction
of the cylinder

14
Two-Handed Safety Control System

Figure 14-10 shows a two-handed safety control circuit. Both palm-button

valves (V1 and V2) must be actuated to cause the cylinder to extend.
Retraction of the cylinder will not occur unless both palm buttons are
released. If both palm-button valves are not operated together, the pilot air
to the three-position valve is vented. Hence, this three-way valve goes into
its spring-centered mode, and the cylinder is locked.

15
Control of Air Motor

Figure 14-11 shows a circuit to control of air motor. When the START push
button valve is actuated momentarily, the air pilot valve shifts to supply air
to the motor. When the STOP push button valve is actuated momentarily,
the air pilot valve shifts into its opposite mode to shut off the supply air to
the motor. The flow control valve is used to adjust the speed of the motor.

16