UNIT IV

PNEUMATIC SYSTEMS AND COMPONENTS

 UNIT IV PNEUMATIC SYSTEMS AND COMPONENTS

• Pneumatic Components:
• Properties of air
• Compressors – Filter, Regulator, Lubricator Unit
• Air control valves
• Quick exhaust valves
• Pneumatic actuators
• Mufflers
• Fluid Power Circuit Design
• Speed control circuits
• Synchronizing circuit
• Pneumo - hydraulic circuit
• Sequential circuit design for simple applications using cascade
Method.
 PNEUMATIC SYSTEM

Pneumatic technology deals with the study of

behavior and applications of compressed air in our
daily life in general and manufacturing automation
in particular.

Pneumatic systems use air as the medium which is

abundantly available and can be exhausted into the
atmosphere after completion of the assigned task.
 Properties of air

Air is a mixture of gases containing 21% oxygen, 78%

nitrogen and 1% others (Argon, CO2, etc.).

The air also contains 4% water vapor due to humidity.

The humidity rate in the air can vary from region to
region and from hour to hour

The atmospheric pressure at this point is 14.7 psi

(1x105 N/m2 ), the sea level being the reference point.
Basic Components of Pneumatic System:
 Basic Components of Pneumatic System:

a) Air filters: These are used to filter out the contaminants from
the air.

b) Compressor: Compressed air is generated by using air

compressors. Air compressors are either diesel or electrically
operated. Based on the requirement of compressed air, suitable
capacity compressors may be used.

c) Air cooler: During compression operation, air temperature

increases. Therefore coolers are used to reduce the temperature of
the compressed air.

d) Dryer: The water vapor or moisture in the air is separated from

the air by using a dryer.
 Basic Components of Pneumatic System:

e) Control Valves: Control valves are used to regulate, control and

monitor for control of direction flow, pressure etc.

f) Air Actuator: Air cylinders and motors are used to obtain the
required movements of mechanical elements of pneumatic system.

g) Electric Motor: Transforms electrical energy into mechanical

energy. It is used to drive the compressor.

h) Receiver tank: The compressed air coming from the compressor

is stored in the air receiver.
Receiver tank
 Receiver tank
• The air is compressed slowly in the compressor. But since the
pneumatic system needs continuous supply of air, this compressed
air has to be stored.

• The air receiver smoothens the pulsating flow from the

compressor. It also helps the air to cool and condense the moisture
present.

• The air receiver should be large enough to hold all the air
delivered by the compressor.

• The pressure in the receiver is held higher than the system

operating pressure to compensate pressure loss in the pipes.

• Also the large surface area of the receiver helps in dissipating the
heat from the compressed air.
 Receiver tank

Generally the size of receiver depends on,

• Delivery volume of compressor.

• Air consumption.

• Pipeline network

• Type and nature of on-off regulation

• Permissible pressure difference in the pipelines

 Compressor:
 It is a mechanical device which converts mechanical
energy into fluid energy.
 The compressor increases the air pressure by
reducing its volume which also increases the
temperature of the compressed air.
 The compressor is selected based on the pressure it
needs to operate and the delivery volume.

 The compressor can be classified into two main types

a. Positive displacement compressors and
b. Dynamic displacement compressor
 Positive displacement compressors include piston
type, vane type, diaphragm type and screw type.
Piston compressors
It produces one pulse of
air per piston stroke. As
the piston moves down
during the inlet stroke
the inlet valve opens
and air is drawn into the
cylinder.
As the piston moves up
the inlet valve closes
and the exhaust valve
opens which allows the
air to be expelled.
The valves are spring
loaded. The single
cylinder compressor
gives significant amount
of pressure pulses at the
outlet port.
The pressure developed
is about 3-40 bar.
 Double acting compressor

 It has two sets of valves and a crosshead. As the piston

moves, the air is compressed on one side whilst on the other
side of the piston, the air is sucked in.
 Due to the reciprocating action of the piston, the air is
compressed and delivered twice in one piston stroke.
 Pressure higher than 30bar can be produced.
 Multistage compressor

As the pressure of the air increases, its temperature rises. It is essential to reduce the air
temperature to avoid damage of compressor and other mechanical elements. It is used to
reduce the temperature of compressed air during the compression stages. The inter-cooling
reduces the volume of air which used to increase due to heat. The compressed air from the
first stage enters the intercooler where it is cooled. This air is given as input to the second
stage where it is compressed again. The multistage compressor can develop a pressure of
around 50bar
 Screw compressor

Piston compressors are used when high pressures and relatively low volume of air
is needed. The system is complex as it has many moving parts. For medium flow
and pressure applications, screw compressor can be used. It is simple in
construction with less number of moving parts. The air delivered is steady with no
pressure pulsation. It has two meshing screws. The air from the inlet is trapped
between the meshing screws and is compressed. The contact between the two
meshing surface is minimum, hence no cooling is required. These systems are quite
in operation compared to piston type. The screws are synchronized by using
external timing gears.
 Rotary vane compressors

The principle of operation of vane compressor is similar to the hydraulic vane pump.
The unbalanced vane compressor consists of spring loaded vanes seating in the slots of the
rotor. The pumping action occurs due to movement of the vanes along a cam ring. The
rotor is eccentric to the cam ring. As the rotor rotates, the vanes follow the inner surface of
the cam ring. The space between the vanes decreases near the outlet due to the
eccentricity. This causes compression of the air. These compressors are free from pulsation.
If the eccentricity is zero no flow takes place.
Lobe compressor
The lobe compressor is used
when high delivery volume but
low pressure is needed. It
consists of two lobes with one
being driven and the other
driving.

It is similar to the Lobe pump

used in hydraulic systems. The
operating pressure is limited
by leakage between rotors and
housing. As the wear increases
during the operation, the
efficiency falls rapidly.
 Dynamic compressors

When very large volume of compressed air is required in applications such as ventilators,
combustion system and pneumatic powder blower conveyors, the dynamic compressor
can be used. The pressure needed is very low in such applications. The impeller rotates
at a high speed. Large volume of low pressure air can be provided by blowers. The
blowers draw the air in and the impeller flings it out due to centrifugal force. Positive
displacement compressors need oil to lubricate the moving parts, whereas the dynamic
compressors have no such need. The efficiency of these compressors is better than that
of reciprocating types.
 Air treatment stages

In the first stage, the large sized particles are prevented from entering the
compressor by an intake filter. The air leaving the compressor may be humid and
may be at high temperature. The air from the compressor is treated in the second
stage. In this stage temperature of the compressed air is lowered using a cooler
and the air is dried using a dryer. Also an inline filter is provided to remove any
contaminant particles present. This treatment is called primary air treatment. In
the third stage which is the secondary air treatment process, further filtering is
carried out. A lubricator introduces a fine mist of oil into the compressed air. This
will help in lubrication of the moving components of the system to which the
compressed air will be applied.
 Fluid Conditioners

Purpose:
To make the compressed air more acceptable and suitable fluid
medium for the pneumatic system components as well as for
operating personnel.

Elements of fluid conditioners

1. Filters
2. Regulators
3. Lubricators
4. Mufflers
5. Air dryers
 Air filter and water trap

Air filter and water trap is used to

• prevent any solid contaminants
from entering in the system.
• condense and remove water
vapor that is present in the
compressed air

The air entering the filter swirls around due to the deflector cone. The centrifugal action
causes the large contaminants and water vapor to be flung out, which hit the glass bowl
and get collected at the bottom. A baffle plate is provided to prevent the turbulent air
from splashing the water into the filter cartridge. At the bottom of the filter bowl there is a
drain plug which can be opened manually to drain off the settled water and solid particles.
Pressure Regulator
Lubricators
FRL Unit