Industrial Pneumatics Overview
Industrial Pneumatics Overview
PNEUMATICS
Topic Outline:
Physical principles of pneumatic
Properties of compressed air
Air generation, preparation and distribution
Function, design and use of pneumatic and electro-pneumatic components
Recognizing and drawing of pneumatic and electro-pneumatic symbols and circuit
diagrams
Pneumatic and electro-pneumatic design of:
> direct and in-direct control
> stroke dependent controls
> logical and/or functions
> pressure dependent controls
> time dependent controls
> counter function
> motion sequences control
What is Pneumatics?
• PNEUMA - Greek root term means “breath”
• It is the industrial implementation and application of
air powered actuators (cylinders and motors) and
their control devices (valves) needed in their
operation.
• Branch of science which deals with the study of
gases especially air, its properties and application at
pressure higher (compressed) or lower (vacuum)
than atmospheric.
Compressed Air as a Working Medium
ADVANTAGES:
Air is available everywhere
Compressed air is easily conveyed in pipelines over large
distances
Compressed air is insensitive to temperature fluctuations
Compressed air need not be returned
Compressed air is explosion proof
Compressed air is clean
Compressed air is fast
Straight line movement can be produced directly
The world of compressed air
Different applications for compressed air
• Pneumatics
• Vacuum applications
• Moving parts
• Bearings
• Cleaning/ antipollution
• Cooling
Compressed Air as a Working Medium
DISADVANTAGES
Compressed air is a relatively expensive means of
conveying energy
It is only economical up to a certain force expenditure
of 20,000 N – 30,000 N
Compressed air requires good conditioning
Air is compressible
Exhaust air is loud (reduced by using silencers)
The oil mist mixed with air for lubricating purposes
exhaust or escapes to the atmosphere
Samples of Industrial Gauges
Boyle’s law
• Pressure is INVERSELY PROPORTIONAL to
the Volume at constant TEMPERATURE
• PV = k ; k = constant
• P1*V1 = P2*V2
• Physical INTERPRETATION :
• Gas or Air is COMPRESSIBLE
The relationship between pressure and volume
Charles law
• P1V1 P2 V2
-------- = -------- = K ; K = CONSTANT
T1 T2
6%
15%
•The major part (79 %) of the costs
for compressed air are caused by
the costs for electrical energy!
79%
• With 15 % and 6 % the costs for
capital investment and
Maintenance costs
Capital investment
Electrical energy costs
maintenance are far below!
Compressed Air Supply
Atmospheric Air
Plant
Types of Compressors
Nitrogen
77,00%
Various Oxygen
0,07% Argon 20,70%
Water 0,90%
1,30%
Carbondioxid
0,03%
Air Service Unit
Consists of an air filter, pressure regulating valve with
pressure gauge and a compressed air lubricator.
Air Filter - filters the compressed air of all impurities and any
condensate it contains.
Pressure Regulator - a reducing valve is assigned the duty
of maintaining a relatively constant operating pressure
regardless of fluctuation and consumption rate.
Compressed Air Lubricator - used to provide the pneumatic
components with sufficient lubrication. These lubricants
inhibit the wearing of all moving parts, keep frictional forces
to a low level, and protect the equipment from corrosion.
PNEUMATIC ACTUATORS
LINEAR CYLINDERS
Single-acting Cylinder
Double-acting Cylinder
ROTARY CYLINDERS
When the piston approaches its final position, the damping piston
shuts off the direct air-outlet. Excess pressure sets up an air-
cushion in the remaining cylinder volume and kinetic energy is
converted into pressure. At this stage, air may only leave the
cylinder through a controlled cross section of stream discharge.
Operation of Double Acting Cylinders with Air
Cushioning
Cushioning sleeves
Seals
Non-return valve
Cushioning adjustment
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
PNEUMATIC VALVES
FUNCTIONS :
regulate pressure
Lines indicate the flow paths, arrows indicate the direction of flow.
The connecting lines for supply and exhaust air are drawn outside the
square.
Directional Control Valve
Ports and Switching Position
Number of ports
2
Number of switching positions
1
2/2 – way valve, normally open position
2
3/2 – way valve, normally closed position
3
1
2
3/2 – way valve, normally open position 1 3
4 2
4/2 – way valve, flow from 1-2 and from 4-3 1 3
4 2
The ball is pressed against the valve seating by a spring and thus,
it shuts off the pressure flow from P to A. When the push rod is
actuated the ball is pushed off of its seat.
2/2-way valve
2 (A)
1
1 (P)
2/2-way valve
2 (A) A0
1 (P)
2/2-way valve
2 (A) A0
1 (P)
2/2-way valve
2 (A)
1
1 (P)
3/2 - way Directional Control
Valve, Normally Open
DEFINITION:
FUNCTIONS:
LOGIC GATES
Adjusting screw
Flow control
needle
Non return valve
Restricted flow
Unrestricted flow
Flow Control Check Valve
Unrestricted flow
Quick Exhaust Valve
P
Quick exhaust valve
A A
P
R
P
Quick exhaust valve
A A
P
R
P
Quick exhaust valve
A A
P
R
P
Quick exhaust valve
A A
P
R
P
Quick exhaust valve
A A
P
R
P
Quick exhaust valve
A A
P
R
P
Quick exhaust valve
A A
P
R
P
Pressure Sequence Valve
ACTUATING DEVICES
PROCESSING ELEMENTS
INPUT ELEMENTS
ENERGY SUPPLY
SWITCHES
POSITONS :
normally open
normally closed
CONTACT
CONFIGURATIONS :
normally open contact
normally closed contact
changeover contact
SOLENOIDS
DEFINITION:
a device which is primarily used as an
electromagnet used to drive a plunger for the
purpose of control actuation.
SOLENOID VALVES
OPERATING PRINCIPLE:
an electric current applied to the solenoid
generates an EMF which moves an armature
connected to the valve stem
2/2 - way Directional Control Valve,
Solenoid Actuated, Spring Returned
PILOT VALVE
Consists of a pneumatic
valve as the signal output
medium and an electrical
switching part, called a
solenoid. An electric current
applied to the solenoid
generates an
electromagnetic force
(EMF) which moves an
armature connected to the
valve stem.
PILOT SIGNAL FLOW
Main Advantages :
PILOT ACTUATES
MAIN VALVE
3/2 - way Directional Control Valve,
Solenoid Actuated, Spring Returned
5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control
5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control
5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control
5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control
5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control
5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control
5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control
5 4 1 2 3
(A) (S) (P) (B) (R)
5/2 - way Directional Control Valve,
Double Solenoid Actuated
Because of the
absence of a return
spring, double solenoid
actuated valves retain
the last signal
administered to them.
They remain in their
last switched position
even with power
removed from both
solenoids.
Effectively, this means
that this valve has
“memory
characteristic”.
Relays
K
A2
2 4
Relay
Cover Symbol
Return spring 12 22
14 24
A1
Armature
Coil
A2 11 21
Contacts
A2 11 21
A1 A2 4 2 1
Relay
Symbol
12 22
14 24
A1
A2 11 21
A1 A2 4 2 1
Relay
Symbol
12 22
14 24
A1
A2 11 21
A1 A2 4 2 1
Relay
Symbol
12 22
14 24
A1
A2 11 21
A1 A2 4 2 1
Advantages of Relays
Logic operations are funcions which link binary signals according to the rules of Boolean algebra. Four basic logic operations are
available for this purpose.
Negation (NOT) The output signal has the opposite value to the input signal.
Conjunction (AND) The output signal only has the value 1, if all the input signals have the value 1
Disjunction (OR) The output signal has the value 1, if at least one of the input signals has the value 1.
Basic electrical circuits
– Function
+24V
+24V
Push Button
Lamp
0V
0V
Basic electrical circuits
– NOT Function
+24V
+24V
Push Button
Lamp
0V
0V
Basic electrical circuits
– OR Function
+24V
+24V
S1 S2
Lamp
0V
0V
Basic electrical circuits
– AND Function
+24V
+24V
S1
S2
Lamp
0V
0V
What are sensors?
A sensor is a technical converter, which converts a
physical value such as temperature, pressure, flow, or
distance, into a different value which is easier to
evaluate. This is usually an electrical signal such as
voltage, current, resistance or frequency of oscillation.
Types of output from Sensors
Binary signal
Analogue signal
Signals
time
SENSORS
Optical Sensor
Inductive Sensor
Optical Sensor
Magnetic Sensor
Sensor Classifications
Sensor Classification Sensor Classification Sensor Classification
According to
Principle of Operation According to According to
Wiring Output Signal Polarity
Contact Sensors
Magnetic
Inductive
Capacitive
Optical
Ultrasonic
SENSORS
TYPES:
Contact Sensors – mechanical in nature, subject to
mechanical wear and with predictable failure rate. Contact sensors
include limit switches, roller switches, and pressure sensors.
PNP Type
+ 18 to 30 Volts DC.
Output is Positive
Output Positive switching
0v
24v DC
Output
Output switches
through to 0v
Negative switching
0v
INDUCTIVE PROXIMITY SENSORS
BN
BK
Note:
For metallic BU
materials only
BN
BK
BU
BN
BK
BU
Optical Sensor
Inductive Sensor
Optical Sensor
Magnetic Sensor
Pneumatic-Electric Converter
D1
R1 C1
R2 K1
-
Switch off Delay Timer
+
S1
D1
R1 C1
R2 K1
-
Sequence Control System
1. The CONTROL CIRCUIT is the part of the relay ladder, which processes
input signals.
2. The POWER CIRCUIT is the part of the relay ladder, which directly
controls the electrical loads. (ie., solenoid coils, motors, lamps, buzzers)
3. In the control circuit, each working step is assigned its own STEP RELAY.
4. Each step relay, except the last step relay, employs a self holding contact.
5. A NO contact of the step relay N is placed in series with the first step relay.
6. A NC contact of the last step relay is placed in series with the first step relay.
Representations
1 2 3 4 5=1
1.0
2.0
Representations
– Chronological Order
Cylinder 1.0 extends and lifts the box
Cylinder 2.0 extends and pushes the box
Cylinder 1.0 retracts, then
Cylinder 2.0 retracts
– Tabular Form
Work Step Motion of Cylinder 1.0 Motion of Cylinder 2.0
1 out -
2 - out
3 in -
4 - in
Representations
– Vector Diagram
Extension represented by 1.0
Retraction represented by 2.0
1.0
2.0
– Abbreviated Notation
Extension represented by : + 1.0 +
Retraction represented by : - 2.0 +
1.0 -
2.0 -
PNEUMATIC APPLICATIONS
Pressing Welding
Automobile
manufacturing
Assembling Painting
Powertrain lines
Welding
FESTO PHILIPPINES:
•Head Office
Festo, Inc.
Km 18, West Service Road,
Sucat, Parañaque City
Tel. No. (02) 776-6888
E-mail: festo@[Link]
Website: [Link]
•Branch Office
Festo, Inc.
Mercedes Commercial Center,
A. C. Cortes Ave., Mandaue City
Tel. No. (032) 345-1120
E-mail: festoceb@[Link]
Thank you for your attention
Thank you very much for your attention.
Hope to see you somewhere again
Benji Jimenez
The End