MODULE 1

PNEUMATIC SYSTEM AND ITS

APPLICATION

Lesson 1 Introduction to
Pneumatics

Lesson 2 Preparation of
Compressed Air

Lesson 3 Conditioning and

Distribution of
Compressed Air

Lesson 4 Pneumatic Actuators

and Air Motors
 Module I | Pneumatic System and its Application 2

MODULE 1

HYDRAULICS AND PNEUMATICS APPLICATION

 INTRODUCTION

This module presents Pneumatic Systems and its Applications. A

pneumatic system uses compressed air to transmit and control energy. It
plays an important role in various industries as a technology in the
performance of mechanical work.

OBJECTIVES

After studying the module, you should be able to:

1. Explain the meaning of pneumatics

2. Explain the various stages of air preparation
3. Explain the importance of fluid conditioners
4. Define the function of a valve

 DIRECTIONS/ MODULE ORGANIZER

There are four lessons in the module. Read each lesson carefully then
answer the review questions to find out how much you have benefited from
it. Work on these exercises carefully and submit your output to your
instructor. Discuss with your instructor in case you encounter difficulty.

Good luck and happy reading!!!

Module 1
 Module I | Pneumatic System and its Application 3

Lesson 1

 Introduction to
Pneumatics

The word ‘pneumatic’ is derived from the Greek word ‘pneuma’,

meaning breathe of air. It is a branch of engineering science dealing with
the study of the behavior and application of compressed air. It can also be
defined as the branch of fluid power technology that deals with the
generation, transmission and control of power using pressurized air.

Pneumatic Systems

Pneumatic Control Systems typically have the following components:

• Drive elements (actuators, air motors)
• Final control elements (directional control valves)
• Signal processing elements (logic gates)
• Signal input elements (push button switches, limit switches,
sensors)
• Energy elements (compressors, filters, dryers, regulators,
lubricators)

Advantage of Using Pneumatics

• High output-to-weight ratio

• Ease of storage
• Easily transferrable from one place to another
• Air is clean and dry
• Air is safe and devices can be protected from overload
• Linear motions are easy to implement with pneumatics
• Easy to recover heat from air

Characteristics of Pneumatic Systems

Quantity Air is available everywhere in unlimited quantity.
Power transmission Compressed air can be easily transmitted through
pipes over long distances.
Storage Large quantities of compressed air can be stored in a
receiver tank.
Energy absorption Air is compressible and elastic. It is capable of
absorbing large amounts of potential energy.
Stalling Because force can be easily controlled in pneumatic
systems, mechanical elements driven by compressed
air system can be stalled for long periods without any
damage.

Module 1
 Module I | Pneumatic System and its Application 4

Over load Compressed air tools and working elements can be

protection subjected to loads even at standstill.
Preparation Pneumatic systems are vulnerable to dirt and
contamination.
Force limitation Compressed air actuators are economical up to 50 kN.
Uniform speed Uniform speeds are hard to achieve with compressed
air.
Noise Exhaust air is noisy and will require appropriate noise
suppression measures.

Applications of Pneumatics

In construction, it is an indispensable source of power for tools such

as air drills, hammers, wrenches, and air cushion supported
structures. In automotive, pneumatics is used for air suspension,
braking, and pneumatic tires.

Some of the industrial applications of pneumatics:

Material handling Manufacturing

Clamping Drilling
Shifting Turning
Positioning Milling
Orienting Sawing
Feeding Finishing
Ejection Forming
Packaging Quality control
Sorting Stamping

Properties of Air

a. Composition
Air is the gaseous form of matter. It has no fixed shape; it conforms
to the shape of its container and readily transmits pressure. Gas has
no fixed volume. It is highly compressible. Air is made up of a mixture
of gases. By volume it contains about 78% nitrogen, 21 % oxygen and
about 1 % of other gases, including argon and carbon dioxide. Air is
colorless, odorless, tasteless, and compressible and has weight.

b. Free air and standard air

• Free air is defined as the air in atmospheric condition at the
point where the compressor is located. Free air will vary with
atmospheric conditions such as altitude, pressure, and
temperature.

Module 1
 Module I | Pneumatic System and its Application 5

•
Standard air is also called normal air. It is defined as the air at
sea level conditions. The condition of normal atmosphere is
used as the basis for getting average values for compressor
delivery volumes, efficiencies, and operating characteristics.
c. Pressure
• Atmospheric pressure is the weight of the column of air on one
square meter of earth’s surface. In pneumatic circuit
calculation, standard atmospheric pressure (101.325 kPa or
14.7 psi or 760 mm of Hg) is used. It is measured using a
barometer.
• Gauge pressure is the pressure measured by a pressure gauge.
Pressure gauges are calibrated to indicate the pressure above
atmospheric pressure.
• Absolute pressure is the true or total pressure.
Absolute pressure = Atmospheric Pressure + Gauge
pressure
Gas Laws

a. Boyle’s Law
If a given mass of a gas is compressed or expanded at a
constant temperature, then the absolute pressure is
inversely proportional to the volume.
b. Charles’ Law
If a given mass of a gas is heated or cooled at a constant
pressure, then the volume is directly proportional to the
absolute temperature.
c. Gay-Lussac’s Law
At constant volume, the absolute pressure of an ideal gas
will vary directly with the absolute temperature.
d. Combined Gas Law
For any given mass of gas undergoing changes in pressure,
temperature, and volume, the general gas equation can be
used. It is the combination of Boyle’s Law, Charles’ Law
and Gay-Lussac’s Law.

Boyle’s Law Gay-Lussac’s Law

Combined Gas
Charles’ Law Law

Module 1
 Module I | Pneumatic System and its Application 6

Think 1.1

1. Define pneumatics.
2. Name five characteristics of pneumatic systems.
3. Name the six basic components of a pneumatic system.

Module 1
 Module I | Pneumatic System and its Application 7

Lesson 2
Preparation of
 Compressed Air

Air Preparation

Pneumatic control systems operate on a supply of compressed

air, which must be made available in sufficient quantity and at a
pressure that suits the capacity of the system. Impurities in the
compressed air such as scale, rust and dust as well as the liquid
constituents in the air which deposit as condensate can cause a great
deal of damage in pneumatic systems. These impurities adversely
affect the functioning and performance of the pneumatic
components. In order to eliminate these effects, compressed air has
to be prepared with great care.

Classification of Air Compressors

a. Reciprocating compressors
• Piston compressor
Piston type compressors are the oldest and most commonly used compressor
in the pneumatic industry because of their flexibility, high pressure
capability, ability to rapidly dissipate heat of compression and being oil-
free. They are built for either stationary or portable services.

 Single Cylinder Compressor

The construction and working of a piston type reciprocating
compressor is very similar to that of an internal combustion
engine.

The piston type compressor consists of a cylinder, cylinder

head, piston with piston rings, inlet and outlet spring-loaded
valves, connecting rod, crankshaft and bearings.

Compression is accomplished by the reciprocating movement of

a piston within a cylinder. This motion alternately fills the
cylinder and then compresses the air. A connecting rod
transforms the rotary motion of the crankshaft into the
reciprocating motion of piston in the cylinder.

Module 1
 Module I | Pneumatic System and its Application 8

Figure 2.1 Single Cylinder Compressor

 Multi-stage piston compressor

In a multi-stage compressor, compression takes place in stages.
For maximum compressor efficiency, it is desirable to cool air
after each stage using an inter-stage cooler.

When the prime mover is connected to the crank shaft, the

crank rotates and the piston in the first stage reciprocates. It
sucks the air through the suction filter and inlet valve. The air,
compressed to a certain degree passes from the left cylinder to
right cylinder through the intermediate cooler. The
compression ratio in the first stage is determined by the
degree of cooling required.

Figure 2.2 Multi-stage Compressor

• Diaphragm compressor
This compressor compresses the air by
using a rotating membrane, to draw air
into the compression area and give it the
pressure to be stored in the storage tube
section.

Figure 2.3 Diaphragm compressor

Module 1
 Module I | Pneumatic System and its Application 9

b. Rotary Type Compressor

The term 'rotary' describes a class of compressors that operate on positive
displacement principle and employs rotary motion to transfer energy.
Popular rotary compressors are twin screw compressors, rotary vane
compressors, lobe type compressors and liquid ring compressors.
• Twin Screw
The twin-screw type compressor consists of two mating helically grooved
rotors, one male and the other female. The male rotor drives the female
rotor. The male rotor has lobes, while the female rotor has flutes.

Figure 2.4 Twin-screw compression cycle: a) intake of gas, b) gas trapped in compressor
housing and rotor cavities, c) compression cycle, d) compressed gas is discharged through
the discharge port
• Rotary Vane
Rotary Vane Compressor is a positive-displacement pump that consists of
vanes mounted to a rotor that rotates inside a cavity. The vane-type
compressor consists of a cylindrical rotor with longitudinal slots in which
radial sliding vanes are fitted. The rotor is positioned eccentrically within a
cylindrical housing.
• Lobe Type
The lobe type air compressor is very simple with no complicated moving
parts. Single or twin lobes are attached to the drive shaft driven by the
prime mover. The lobes are displaced by 90 degrees. Thus, if one of the
lobes is in horizontal position, the other at that particular instant will be in
vertical position. The air gets trapped in between these lobes and as they
rotate, gets compressed and delivered to the delivery line.
• Liquid Ring
They use liquid that is centrifuged in a specifically shaped casing. The liquid
can be water, sulphuric acid, crude oil, gasoline or any other liquid that
does not react with the gas that has to be compressed. This specific feature
reduces the wearing off of the metallic parts theoretically to zero, and
therefore maintain their efficiency for a long time.
c. Turbo Compressor
These compressors raise the pressure of air or gas by imparting velocity or
energy and converting it to pressure energy. First, rapidly rotating impellers

Module 1
 Module I | Pneumatic System and its Application 10

(similar to fans) accelerate the air. Then the fast flowing air passes through
a diffuser section that converts its velocity head into pressure by directing it
into a volute. These compressors can be:
• Centrifugal
• Axial Flow

Desirable Qualities of Compressed Air

• It must be cleaned.
• It must be cooled.
• It must be dried.

After Cooler
The compressed air discharged from an air compressor is hot and contains
large quantities of water in vapour form. After coolers are heat exchangers
for cooling the discharge from an air compressor. They use either air or
water and are an effective means of removing moisture from the
compressed air.
Functions of compressed air after coolers
• Cools air discharged from air compressors via the heat
exchanger
• Reduces risk of fire (hot compressed air pipes can be a
source of ignition)
• Reduces compressed air moisture level
• Increases system capacity
• Protects downstream equipment from excessive heat

Types of after coolers

a) Air-Cooled after cooler
Air-cooled after coolers provide economical cooling by using ambient air to
cool the hot compressed air from air compressors. They cool the hot
compressed air leaving the compressor at a temperature of approximately
100°C to 150°C to the desired inlet temperature of an air dryer, which is
approximately 35°C to 50°C. As the compressed air cools, about 75% of the
water vapour present condenses into liquid water, which should be
immediately removed from the system with a separator.
b) Water-cooled pipeline after cooler
The most common style for compressed air service is a shell and tube heat
exchanger. The pipeline after cooler consists of a shell with a bundle of
tubes fitted inside. Typically, the compressed air flows through the tubes in
one direction as water flows on the shell side in the opposite direction. The
heat from the compressed air is transferred to the water. As the compressed
air cools, water vapour forms.

Module 1
 Module I | Pneumatic System and its Application 11

Drying of compressed Air

Drying of compressed air lowers the dew point of the compressed air by
removing the moisture from it.
Types of Air Dryers
a) Absorption Type dryer
Absorption drying is a purely chemical process. The moisture in the
compressed air forms a compound with a drying agent like phosphorous
pentaoxide in the tank. This causes the drying agent to break down. It is
then discharged in the form of a fluid at the base of the tank.
b) Adsorption Type dryer
Adsorption is a physical process of moisture removal from the porous surface
of certain granular materials. Gaseous molecules are attracted to certain
solid surfaces by van der Waals forces and this causes adsorption. The
degree of attraction or adsorption depends on the properties of the gaseous
molecules and the desiccant. Most commonly used desiccants are activated
alumina, molecular sieves and silica gel.
c) Refrigeration dryer
This drying method is based on the principle that if the compressed air is
cooled to a temperature below the dew point, condensation takes
place and water is precipitated. Almost all the water and oil particles
get condensed and collected in the water traps provided at
appropriate points. The cooled compressed air is then filtered to
remove from it the suspended solid particles and most of the oil mist.

Figure 2.5 Types of air dryer

a. Absorption type b. Adsorption type c. Refrigeration type

Module 1
 Module I | Pneumatic System and its Application 12

Table 2.1 Comparison of Air Dryer Types

Type Advantages Disadvantages

Absorption Pressure dew point + Inlet temperature must not exceed
16°C 30C
Low Capital Cost Drying agents are consumables and
therefore must be regularly
replenished. Highly corrosive
chemicals are used. They are not
environment friendly.
Refrigeration +3°C pressure dew Output dew point will vary with the
point approach temperature at the inlet
and cleanliness of the heat
Input temperature can exchanger.
be as high as 16°C
Adsorption Achievable pressure High capital cost
dew point of -40°C

High operating cost

Use of micro-filters to prevent the
residue from chemical adds to the
cost

Storage of Compressed Air

Air Receivers
Receivers perform several functions in compressed air systems.
Firstly, they provide larger system capacity, which increases the
cycle time of the compressor control systems. This makes the
elimination of unstable and over correcting control cycles less
difficult.
The receiver also dampens pulsations from reciprocating
compressors, acts as a reservoir to prevent excessively temporary
pressure drop during sudden short-term demand, and can be used to
smoothen the air flow through dryers, separators and other air-
conditioning equipment.

Module 1
 Module I | Pneumatic System and its Application 13

Components of an air receiver

a. Safety Valve – used to release the excess pressure of stored air.
b. pressure gauge & temperature gauge – used together with pressure
switches to control the on-off of the compressor and for remote
alarms.
c. drain cock – allows the removal of condensed water.

Figure 2.6 Air Receiver

Think 1.2

1. Explain the different stages of preparation of compressed air.

2. What is the function of an after cooler?
3. What are the different methods of drying compressed air?
4. List two functions of air receivers.

Module 1
 Module I | Pneumatic System and its Application 14

Lesson 3

 Conditioning and Distribution

of Compressed Air

Fluid Conditioners
The atmospheric air taken into the compressor contains contaminants
like dirt, smoke and water vapour. Contaminated air can lead to
excessive wear on, and failure of pneumatic components. Therefore,
fluid conditioners are used to provide clean, dry and contamination
free compressed air.

The purpose of fluid conditioners is to make the compressed air an

acceptable fluid medium for the pneumatic system as well as the
operating personnel. The following fluid conditioners are used in
pneumatic systems:

a) Air Filters
The Purpose of an air filter is to clean the compressed air
of all impurities and any condensate it contains. It consists
of a filter cartridge, a deflector, a bowl, and water drain
valve.

Figure 3.1 Construction of an Air Filter

Module 1
 Module I | Pneumatic System and its Application 15

Functions of Air Filters

• To remove foreign matter and enable clean, dry air to flow
unrestricted to the regulator and onto the lubricator
• To condense and remove water from the air
• To arrest fine particles and all solid contaminants in the air

Types of contamination in a compressed air system

• Atmospheric dirt
• Water vapour, condensed water and water aerosols
• Rust and pipe scale
• Micro-organisms
• Liquid oil and oil aerosols
• Oil vapour

b) Air Regulators
The function of an air pressure regulator is to maintain the
working pressure at a constant level despite line pressure
and air flow fluctuations. When the pressure is too low, it
results in poor efficiency, and when the pressure is too high
it leads to wasted energy and degradation of equipment
performance.
In pneumatic systems, the pressure is generally regulated in
two places: a) at the receiver tank and b) in the load
circuits.

Figure 3.2 Construction of an Air Regulator

Module 1
 Module I | Pneumatic System and its Application 16

c) Air Lubricators
The function of an air lubricator is to add a controlled
amount of oil to the air to ensure proper lubrication of the
internal moving parts of a pneumatic system. Lubricants are
used to:
• Reduce wear on moving parts
• Reduce frictional losses
• Protect equipment from corrosion

Figure 3.3 Construction of an Air Lubricator

d) Filter-regulator-lubricator (FRL) unit

In most pneumatic systems, the compressed air is first
filtered and then regulated to a specific pressure before
passing through the lubricator for oil treatment. So a filter,
regulator and lubricator are placed in that order along the
inlet line of each air circuit. They may be installed as
separate units, but more often, they are in the form of a
combined unit.

Figure 3.4 An FRL unit: a) 3D View b) detailed symbol, c) simplified symbol of FRL

Module 1
 Module I | Pneumatic System and its Application 17

Figure 3.5 Installation of FRL units

Air Distribution System

The main objective of an air distribution system is to provide a leak-

proof distribution channel for compressed air while keeping the pressure
drop within permissible limits. The air distribution system consists of
conductors and fittings which interconnect various components of a
pneumatic system.

The air distribution should take into account the following parameters:

 Choice of fluid conductor

Fluid conductors used in pneumatic applications carry air from the
reservoir to the actuator and then to the atmosphere. Fluid
conductors are generally divided into three classes:
 Rigid Pipe are used in main air distribution system.
Copper, steel, iron, and aluminum are the most common
materials used.
 Semi Rigid Tubing are used to conduct clean and dry air
to pneumatic tools and equipment. Plastic tubes, nylon,
and polyurethane are the materials used.
 Flexible Hose are used to bend lines or to connect
compressor air source to actuators that are located on
movable parts. Natural and synthetic rubber are the
material used,

Module 1
 Module I | Pneumatic System and its Application 18

 Flow Resistance
The flow of compressed air through a piping creates friction, which
leads to a pressure drop. A pressure drop cannot be avoided, but can
be considerably reduced by routing pipes properly and assembling the
fittings correctly.

 Correct sizing of pipes

The pipe size should be selected properly to keep the pressure drop
to a minimum over the entire air distribution system. Selection is
governed by the following factors:
 Delivery volume
 Length of piping
 Number of restrictions in the system
 Operating pressure in the system
 Permissible pressure drop
 Number of fittings
 Flow velocity of air

 Correct sizing of fittings

Air mains are usually made with steel pipes with welded joints since
welds are more durable than screwed joints over long term. A
disadvantage of welding is the formation of scales during the process,
leading to rust over time. The advantages of welding pipes are tight
sealing of joints and lower costs. Pipes made of commercial grade DIN
2448 and DIN 2458 are used.

An alternative means of making a pipe connection is to use a screw

union or a bite sleeve or compression sleeve. These are fitted on
thin-walled, seamless, drawn steel pipes. They allow for easy
disconnecting or rearranging of sections of the overall piping layout.

Figure 3.6 Screw unions for pipe

Module 1
 Module I | Pneumatic System and its Application 19

Table 3.1 Common fittings used in the pneumatic industry

Elbow male Equal cross Straight Straight Straight male

adaptor connector connector female adaptor
fitting

Straight male Swivel elbow Swivel tee Bulk head Rigid

fitting adaptor connector manifold

Equal parallel Swivel elbow Straight Male to Swivel angle

V connector adaptor adaptor female union fitting

Swivel V Side T Swivel V Swivel elbow Swivel Tee

adaptor adaptor female adaptor adaptor
adaptor

 Pipe Material
Air mains make up a large portion of the initial cost of a compressed air
installation. Reducing the pipe diameter lowers the investment cost but
results in a higher air pressure drop which increases operational
expenses, more than offsetting the initial savings.
- Stainless steel pipes are used in long straight main lines when
larges diameters are required.
- Copper tubes are used where corrosion and heat resistance, as
well as high rigidity are required.
- Rubber hose or reinforced plastic is suitable for air actuated hand
tools as it offers freedom of movement for the operator.
- Plastic tubing is commonly used to connect pneumatic
components, and is easy to cut and fit for quick connections as
long as the operational conditions are within its temperature
tolerance range.

Module 1
 Module I | Pneumatic System and its Application 20

 Pipe Layout
Accurate layout is the decisive factor in determining cost effective
operation of the compressed air system. Lines for the distribution of
air power must be properly installed and must be sized to provide
adequate supply of air for each work station. The two principle
factors affecting the pressure drop in air systems are leaks and
friction.

Air distribution is arranged in two types of layouts:

i. Manifold Layout
This layout is simple and less expensive. It is also called a leader system
and is effective for adequate distribution of air to several tools
simultaneously. This layout has the advantage of distributing compressed
air over the shortest possible run, reducing the pressure drop and
economising on piping cost. Its chief disadvantage is its lack of
flexibility.

Figure 3.7 Manifold type pneumatic network

ii. Ring Layout

As actuating devices consume air, pressure is decreased downstream.
Using the ring main layout helps counter this effect. Demand is met from
two directions and this ensures uniform pressure conditions in the air
network.

Figure 3.8 Ring type pneumatic network

Module 1
 Module I | Pneumatic System and its Application 21

Three ways to remove water from the air in the distribution

system:

1. Bent drop leg

Run a pipe or hose line with a drop leg that bends the tube or pipe
upwards rather than directly to the point of use unit. This way, water
gets separated by the action of gravity. The collected water can be
periodically drained using a manual or automatic drain.

Figure 3.9 Bent drop

2. Sloping distribution line

All the take-off points are tapped from the top of the pipe to prevent
the entry of water into the branch lines. An automatic drain valve
can be provided for terminating the dead leg. With this arrangement,
accumulated water can be automatically drained off when the
pressure is on or when the system is shut down. For effective
drainage, the pipe should be inclined 1 to 2% downwards in the
direction of the area of flow.

Figure 3.10 Sloping distribution line

3. Automatic Drain
Drainage points are provided using equal tees. Water separation is
achieved by arranging them to redirect the flow.

Figure 3.11 Automatic drains in the ring

Module 1
 Module I | Pneumatic System and its Application 22

Think 1.3

1. State the importance of fluid conditioning.

2. Describe the function of an air filter.
3. Describe the function of an air pressure regulator.
4. Describe the function of an air lubricator.
5. Discuss three ways to remove water from the air in an air distribution
system.

Module 1
 Module I | Pneumatic System and its Application 23

Lesson 4

 Pneumatic Actuators
and Air Motors

Pneumatic actuators are devices used to convert the pressure energy of

compressed air into mechanical energy to perform useful work. Actuators
are also used to perform the task of exerting the required force at the end
of the stroke, or used to create displacement by the movement of the
piston. Pressurized air from the compressor is stored in the reservoir from
where it is supplied to the pneumatic actuator to do work.

Types of Pneumatic Actuators

• Linear actuators or pneumatic cylinders
• Rotary actuator or air motors

Types of Pneumatic Cylinders (Linear Actuators)

Pneumatic cylinders are devices that convert air pressure into linear
mechanical force and motion.

a. Single acting cylinders

A single acting cylinder has one working port. Forward motion of the piston
is obtained by supplying compressed air to the working port. Return motion
of the piston is obtained by the spring placed on the rod side of the cylinder

Applications of Single Acting Cylinders

- Single Acting Cylinders are used where force required is to be
exerted only in one direction.
- Example:
o Clamping
o Feeding
o Sorting
o Locking
o Ejecting
o Braking

Module 1
 Module I | Pneumatic System and its Application 24

Construction features of a single acting cylinder

Figure 4.1 Construction features of a single acting cylinder

b. Double acting cylinders

Double acting cylinders are equipped with two working ports, one on the
piston side and the other on the rod side. For forward motion of the cylinder
compressed air is admitted on the piston side, and the rod side is connected
to the exhaust. During the return stroke, air admitted in the rod side while
the piston side is connected to the exhaust.

Figure 4.2 Schematic of a double-acting cylinder

Construction features of a double acting cylinder

Seven parts of a double acting cylinder are:

• Base cap
• Bearing cap
• Cylinder barrel
• Piston
• Piston Rod
• Scraper rings
• Seals

Figure 4.3 Construction features of a

double-acting cylinder

Module 1
 Module I | Pneumatic System and its Application 25

Graphic Symbols for Cylinders

Name of cylinder Symbol

Single-acting cylinder

Double-acting cylinder

Double-acting cylinder with double

ended piston rod

Double-acting cylinder with non-

adjustable cushioning in one
direction

Double-acting cylinder with

adjustable cushioning

Double-acting cylinder with non-

adjustable cushioning at both ends

Module 1
 Module I | Pneumatic System and its Application 26

Cylinder Mountings

• Fixed Centerline Mounting

• Pivoted Centerline Mounting
• Fixed non-Centerline Mounting

Fixed Centerline Pivoted Centerline Fixed non-Centerline

Mountings Mounting Mounting

Blind end flange Rod end trunnion End lug mount

Rod end flange Blind end trunnion Side lug mount

Centerline Lugs Clevis Integral key mount

Tie rod mount Central trunnion Flush mount

Rotary Actuators

Rotary actuators are used to achieve angular motion and produce

high torque output while having limited rotary movement.
Designs of Rotary Actuators

a) Vane Type actuators

Vane type actuators are essentially mechanically connected linear actuators
that convert a linear force to an output torque and rotational movement.
These devices are capable of providing an output motion of more than one
revolution but not continuous rotation.

Module 1
 Module I | Pneumatic System and its Application 27

Types of Vane Type Actuators

i. Single vane limited rotation actuators
ii. Double vane limited rotation actuators

Figure 4.4 Vane actuators (i) single vane (ii) double vane

b) Rack and pinion rotary actuator

These are special duty rotary actuators with a high torque and a small
footprint. They have double pistons that transmit turning motion to the
output shaft. The toothed piston rods act on the output shaft in a rack-and-
pinion arrangement to produce an even turning moment throughout the
rotation.

Figure 4.5 Vane actuators rack and pinion rotary actuator

c) Helix spine rotary actuator

It consists of a hollow piston with internal spiral grooves. Only rotational
movement of the spiral shaft is possible. If fluid is supplied to the CW port,
the direction of rotation of shaft is clockwise. If fluid is supplied to the CCW
port, the direction of the rotation of shaft is counter clockwise.

Figure 4.6 Vane actuators Helix spine rotary actuator

Module 1
 Module I | Pneumatic System and its Application 28

Air Motors
Air motors are high power, high weight, compact and dependable units
requiring little maintenance over long periods of use.
Advantages of air motors
• Completely safe on conditions where electric motors might create
a risk of fire or explosion,
• Can be readily be adjusted for speed by varying the pressure of
the air supply via a regulator
• Air motors cannot be damaged by overload; they simply slow down
or stop before damage occurs.
• Many types of air motors are reversible.

Types of Air Motors

 Vane air motor

Vane air motors are normally preferred for applications requiring low or
medium power, particularly as they can be made simple and compact in
design. They are used extensively in portable tools, multiple tool assemblies
for mass production lines, conveyor belts, hoists, pumps, tractors.
 Piston air motor
Piston type motors are less subject to changes in speed with varying loads
than vane motors, and are usually preferred for heavier loads or where
powerful low speed torques are required.
 Diaphragm air motor
Diaphragm motors are quite distinct and are basically oscillators rather than
motors, deriving a rotary output via a ratchet engaging with a toothed
wheel. They are particularly suitable for applications demanding extreme
accuracy of control at high and low torque, such as valve operation.
 Turbine motor
These high speed motors generate only a small torque. In fact, when
stalled, the torque is practically negligible. Speeds are limited to between
50,000 RPM to 80,000 RPM and the torque is the highest in the middle of this
range. Application is limited to where high speeds combined with light loads
are required, e.g., high- speed pencil grinders and dental drills.
 Gear motor
These motors are categorized as dynamic motors. The mating gears are of
three types: straight, helical or double helical. These are pure displacement
motors, that is, they don't use the expansion properties of compressed air
and have low volumetric efficiency.

Module 1
 Module I | Pneumatic System and its Application 29

Advantages of gear motors

1. Very high speeds are possible.
2. The motor is oil free.
3. There is no wear.
4. They are suitable for continuous operation.

Think 1.4

1. What is the function of a pneumatic actuator?

2. Explain the working of a double acting cylinder with a neat sketch.
3. Give five applications of pneumatic cylinders.
4. Differentiate single acting pneumatic cylinder from double acting
cylinder.
5. What are the advantages of air motors?

Module 1
 Module I | Pneumatic System and its Application 30

 MODULE SUMMARY

In module I, Pneumatic Systems and its Applications. You have

learned its definition and application, its characteristics, the various stages
of preparation and distribution of compressed air, and pneumatic actuators.

There are four lessons in module I.

Lesson 1 explained the meaning of pneumatics, its advantages, and

applications.

Lesson 2 explained the various stages of air preparation, described the

working of various compressors, and described the various functions of an
after cooler.

Lesson 3 explained the importance of fluid conditioners, listed factors for

the selection of components of a pneumatic network, and explained the
various compressed air network systems.

Lesson 4 explained the meaning of a pneumatic actuator, classified the

various types of pneumatic actuators, and explained the working of various
pneumatic actuators.

Congratulations! You have just studied Module I!

Module 1
 Module I | Pneumatic System and its Application 31

REFERENCES

Jagadeesha, T. (2015). Hydraulics and Pneumatics. K International

Publishing House.

Jagadeesha, T. (2015). Pneumatics: Concepts, Design and Applications.

Graphica Printers, Hyberabad. Universities Press (India) Private Limited.

Croser, P., Ebel F. (2002). Pneumatics (Basic Level). Festo Didactic GmbH &
Co.

Waller, D., Werner, H. (2002). Electropneumatics (Workbook Basic Level).

Festo Didactic GmbH & Co.

Module 1