PNEUMATICS AND

ELECTRO-PNEUMATICS TECHNOLOGY

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 Principles of pneumatics
Pnuematics defined

• Pnuema – Air (wind or breath in

ancient Greek)
• Matic – movement

• Itmeans control movement of air

• In industries, it is referred as the
used of compressed air to transmit
power or/and motion

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 Principles of pneumatics
MOST ENERGY SOURCE

• Electricity
• Hydraulics
• Pneumatic
• Etc

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 Principles of pneumatics
Why Pnuematic? The advantages:
• Cheap – Air is available in unlimited
supply
• Air is non-explosive and non-toxic
• Compressed air can be transmitted over
long distance
• Compressed air can be stored
• Fast
• Easily control the speed and movement
• Clean
• Overload proof

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 Principles of pneumatics
Disadvantages:
• Air absorbs moisture and drying may
have to be considered
• The exhaust air causes noise. Sound
absorbers may be required
• Pressure limit which can be used in a
compressed air system
• Smooth and even movement not
possible

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 Principles of pneumatics
Pneumatics is used in carrying out
machining and working operations.
For example:
• Drilling
• Turning
• Milling
• Sawing
• Finishing
• Forming
• Quality control

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 Principles of pneumatics
Application example: Conveyor line diverter

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 Principles of pneumatics
Application example: Pneumatic cutter

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 Principles of pneumatics
Unit for pressure
• PSI

• Pa

• Bar (normally used in industries)

• N/m2 (SI unit)

- Gauge pressure vs absolute

pressure
- Vacum
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 Principles of pneumatics
ELEMENTS OF PNUEMATICS SYSTEM
• Energy supply, source

• Input elements, input signal

• Processing elements, processor

signal
• Final control element, control signal

• Actuating devices, output

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 Principles of pneumatics

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 Principles of pneumatics

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 Electro-pneumatic System
• Combination of electrical control and
pneumatic technologies

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 Electro-pneumatic System

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 Electro-pneumatic System
Advantages of electro-pneumatic:
• Higher reliability (fewer moving parts
subject to wear)
• Lower planning and commissioning
effort particularly for complex controls
• Lower installation effort, particularly
when modern components such as valve
terminal are used
• Simpler exchange of information
between several controllers

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 Pnuematic System and Air Generation
ENERGY SUPPLY UNIT (AIR GENERATION)

• Air compressor
• Air receiver/reservoir
• Air cooler
• Air dryer
• Service unit – Filter, Regulator &
Lubricator (FRL unit)

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 Pnuematic System and Air Generation
Compressed air distribution
system:

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 SYMBOL FOR ENERGY SUPPLY UNIT

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 SYMBOL FOR ENERGY SUPPLY UNIT

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 Energy Supply Unit
TYPE OF COMPRESSOR
• Reciprocating

- piston
- diaphragm
• Rotary

- vane
- screw
• Flow compressor

- axial flow
- radial flow

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 Energy Supply Unit
Type of compressor

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 ENERGY SUPPLY UNIT
Type of compressor

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 Type Of Compressor

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 Type Of Compressor

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 Air Drying
Refrigeration Drying

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 Refrigeration Drying

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 AIR DRYING
Absorption and Adsorption drying

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 ABSORPTION DRYING

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 ADSORPTION DRYING

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 ENERGY SUPPLY UNIT
SURVICE UNIT
• Compressed air filter

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 COMPRESSED AIR FILTER

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 SERVICE UNIT
Pressure regulating valve

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 PRESSURE REGULATING VALVE

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 SERVICE UNIT
Compressed air lubricator

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 COMPRESSED AIR LUBRICATOR

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 Pneumatic Symbols and Standard

Directional Control Valves

Switching position

Flow path

Flow path blocked

Connection ports

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 Pneumatic Symbols and Standard

2
2 - Way valve

Number of switching positions

Number of ports

3
2 - Way valve

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 Pneumatic Symbols and Standard
Directional control valves

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 Pneumatic Symbols and Standard
Port designation

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 Port designation

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 Input Elements Valve
Types of actuation

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 Input Elements Valve
Types of actuation

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 Pneumatic Symbols and Standard
Non-return, flow control and pressure control valves

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 Pneumatic Symbols and Standard
Non-return, flow control and pressure control valves

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 Pneumatic Working Elements
Linear:
• Single acting cylinder
• Double acting cylinder
• Rodless cylinder

Rotary:
• Rotary actuator
• Swivel drive/cylinder

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 Pneumatic Working Element
Single acting cylinder

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 Single Acting Cylinder

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 Single Acting Cylinder
Bellow / membrane cylinder

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 Pneumatic Working Element
Double acting cylinder

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 Double Acting Cylinder
• With out cushioning

• With cushion

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 Cylinder Construction

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 Type Of Mounting

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 Type Of Mounting

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 Type Of Mounting

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 Type Of Mounting
Rod end mountings

UF
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 Rodless Cylinder

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 Rodless Cylinder

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 Rotary Cylinder & Swivel Drive

Swivel Drive

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 Rotary Cylinder & Swivel Drive

Rotary cylinder

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 Force Calculation
Pascal’s Law:
pressure exists when a force F is imposed on an
enclosed fluid with a surface A, The pressure exerts
an equal effect on all points of the surfaces.

F
P= N/m2
A
F
P

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 Force Calculation
Theoretical Force: Fth
Fth is the calculated force based on Pascal’s Law
without consideration of all the resistance
forces.

Frictional Resistance: Ff
To be considered during extend and retract
strokes. Estimated at about 10 to 12% of Fth.

Spring Resistance: Fsp

To be considered when using spring loaded
single acting cylinders. Estimated at about 15%
of Fth.

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 Force Calculation
Example 1:
A double acting cylinder is used to
transfer work-pieces in a production
machine. Determine the extend and
retract forces if the piston diameter of
the cylinder is 80mm, rod diameter
15mm and the pressure used is 6bar.
Assume frictional force is 10% of
theoretical force.

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 Force Calculation
Example 2:
A clamping vice uses a single acting cylinder
to clamp the work-pieces. Determine the
extend force if the piston diameter of the
cylinder is 80mm, rod diameter 15mm and
the pressure used is 6bar. Assume frictional
and spring forces are 10% and 15% of
theoretical force respectively.

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 Design and construction of pneumatic control circuits

Exercise 1.

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 Design and construction of pneumatic control circuits
Exercise 2.

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 Design and construction of pneumatic control circuits

Components designation

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 Design and construction of pneumatic control circuits

Components designation: Example

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 Design and construction of pneumatic control circuits

Direct and indirect actuation

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 DIRECT ACTUATION

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 INDIRECT ACTUATION

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 Pneumatic Control Devices
Directional Control Valves

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 Directional Control Valves

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 Directional Control Valves

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 Directional Control Valves

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 Directional Control Valves

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 Directional Control Valves

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 Directional Control Valves

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 Directional Control Valves

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 Directional Control Valves

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 Pneumatic Control Devices
Shuttle Valve (OR)

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 Shuttle Valve (OR)

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 Pneumatic Control Devices
Dual Pressure Valve (AND)

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 Dual Pressure Valve (AND)

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 Design and construction of pneumatic control circuits
EXERCISE 3.

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 SHUTTLE VALVE (OR FUNCTION)

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 Design and construction of pneumatic control circuits

EXERCISE 4.

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 DUAL PRESSURE VALVE
(AND FUNCTION)

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 Pneumatic Control Devices
One-way Flow Control Valve

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 One-way Flow Control Valve

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 One-way Flow Control Valve

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 Design and construction of pneumatic control circuits

EXERCISE 5.

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 5/2 WAY DOUBLE PILOT VALVE (SPEED CONTROL)

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 Design and construction of pneumatic control circuits
Exercise 6.
A container of washers is to be dipped in and out of the cleaning
bath by using a double acting cylinder. The start and stop for this
continuous movement is to be achieved by actuating the ‘START’
and ‘STOP’ pushbuttons each.
On actuating the ‘STOP’ pushbutton, the container should stop at the
top. The speed for forward and retract strokes are controllable.

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 ELECTRO PNEUMATIC

 Pneumatic Vs electro-pneumatic
 Electro-pneumatic component
 Electrical component
 Electro-pneumatic controller
 Design and construction of electro-
pneumatic control circuits

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 Electro-pneumatic components
Function of solenoid
 A magnetic field is

induced when a current

passed through an
electrical conductor
 A soft iron core

(amature) is drawn into

a coil through which
the current is flowing

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 Electro-pneumatic components
Solenoid Valves

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 Solenoid Valves

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 Solenoid Valves

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 Solenoid Valves

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 Solenoid Valves

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 Solenoid Valves

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 Solenoid Valves

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 Electrical components

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 Electrical components

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 Electrical components

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 Electrical components

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 Design and construction of elctro-pneumatic control circuits
Exercise 7:
Using a sorting device, parts are to be transferred from conveyor belt.
By pressing the pushbutton switch, the piston rod of a single-acting
cylinder pushes the part off the conveyor belt. When the pushbutton is
released, the piston rod returns to the retracted end position.

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 Design and construction of electro-pneumatic control circuits
Exercise 8:
Using a special device, the valve in a pipe line is to be opened
and closed. The valve is opened by pressing the pushbutton
switch. When the pushbutton is released the valve is closed.

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 Design and construction of electro-pneumatic control circuits
Exercise 9:
Wooden planks are to be pushed along from a gravity feed
magazine to a clamping device. By pressing a pushbutton switch
one plank is pushed by the slide out of the gravity feed magazine.
After the slide has reached the forward end position it is returned
to its start position.

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 Electrical components

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 Design and construction of electro-pneumatic control circuits

Exercise 10:
Using a conveyor belt, parts are to be transported in linear
timed sequence to work stations which are arranged in line after
one another. When the latching pushbutton (or selector) switch
is activated the main wheel is indexed by the oscillating piston
rod of a cylinder via a pawl. When the pushbutton (or selector)
switch is activated again the drive is switched off.

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 Electrical components
Relay
Cover Armatur
Return 1 2
e A 1 2
spring 2 2
1 4 4

Coil
A2 1 21
1
Symbol
Contacts

Coil
connection Contact
s connections
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 Relay
12 22
A1 14 24

A2 11 21

Symbol

A1 A2 4 2 1

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 Relay
12 22
14 24
A1

A 1 2
2 1 1
Symbol

A1 A2 4 2 1

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 Design and construction of electro-pneumatic control circuits
Exercise 11:

Repeat the exercise 10 but the

conveyor is controlled by using ‘Start’
and ‘Stop’ pushbuttons.

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 Electro-pneumatic controller

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 Electro-pneumatic controller

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 Electro-pneumatic controller

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 Electro-pneumatic controller

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 Electro-pneumatic controller

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 Electro-pneumatic controller

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 Electro-pneumatic controller

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 Electro-pneumatic components
Pressure Switch

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 Design and construction of electro-pneumatic control circuits
Exercise 12:
Parts are to be stamped with a stamping device. By pressing two
pushbutton switches the die is pushed down and the part is
stamped. When the stamping pressure has been achieved the die
is returned to its start position.

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 Electrical components
Time relay (Timer)
Two types:
•Pull-in (on) delay and
•Drop-out (off) delay

Pull-in (on) delay

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 Time relay (Timer)
Pull-in (on) delay Timer

Signal behavior:
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 Time relay (Timer)
Drop-out (off) delay

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 Time relay (Timer)
Drop-out (off) delay

Signal behavior:

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 Design and construction of electro-pneumatic control circuits
Exercise 13:
Using a hot pressing die, packing material is to be sealed by
application of heat. By pressing a pushbutton switch the heating rail
is advanced and the packaging material is heated along the adhesive
strip. After the adhesion time of 10 seconds has reached, the heating
rail is returned to its start position.

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 Design and construction of electro-pneumatic control circuits
Exercise 14:
Using a transfer station blocks are to be transferred from a magazine to a
processing station.
The blocks are pushed out of the magazine by cylinder 1A and transferred to the
processing station by cylinder 2A. The piston rod of cylinder 2A may only return
when the piston rod of cylinder 1A has reached the retracted end position. The
magazine is monitored by means of a limit switch. If there are no more blocks in the
magazine, it is not possible to start the cycle. This is indicated by means of an
audible signal. The control is to be operated in single cycle.

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 Control of Multiple Cylinders
Chronological sequence is simplified
by using:
• Displacement step diagram (pictorial)

• Vector diagram

Example: 1A→ 2A→ 2A← 1A←

• Abbreviation notation

Example: 1A+ 2A+ 2A- 1A-

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 Design and construction of electro-pneumatic control circuits
Exercise 15:
Workpieces are inserted into the clamping device by hand. Clamping
cylinder 1A is to extend when the start button is pressed. When the
workpiece is clamped, it is to be drilled via feed unit 2A and the drill
retracted once again. Then, the clamping cylinder 1A is to release the
workpiece.

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 Design and construction of electro-pneumatic control circuits

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 Control of Multiple Cylinders
Methods for construction a circuit diagram
Two primary methods:
• Intuitive method - conventional or trial and error
methods.
• Methodical design I accordance with prescribed
rules and instructions.

Signal overlaps
Overcome by signal cut-out through:
1) Components
• Idle roller limit switch
• Timer

2) Circuit
• Electrical Cascading Circuit
• Electrical Shift register

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 THE END
THANK YOU

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