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Pneumatics 11
 MODULE 3

PNEUMATICS

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Pneumatics 22
 TPM Education &
Training
Subcommittee
Presents …

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Pneumatics 33
 In this Training Pack we will cover –

 Introduction
 Air Cylinders
 Direction & Flow Control Valves
 Pneumatic circuits
 Exercises

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Pneumatics 44
 Introduction

Pneumatics finds wide application in

industry.
The actual tasks are performed by Air
Cylinders. Direction and Flow Control
Valves are control devices that regulate
operations of air cylinders.
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Pneumatics 55
 Air Cylinders

 Air cylinder is an output device. It

consumes compressed air and gives
linear movement.
 It is used for moving objects, closing
machine guards, punching parts,
advancing slides, clamping parts etc.

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Pneumatics 66
Air Cylinders are classified as Single Acting
and Double Acting

Air Cylinders

Single Acting Double Acting

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Pneumatics 77
 Single Acting Cylinder

Body Return Spring Piston Rod

Exhaust port

Airline thru’ direction control valve

connected here.

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Pneumatics 88
 Single Acting Cylinder

Air line exhausted

When air line is exhausted (that is not pressurized

but open to atmosphere), return spring keeps the
piston IN.

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Pneumatics 99
 Single Acting Cylinder

When air line is pressurized (that is connected to

compressed air), force developed by air pressure is
stronger than the spring and piston moves OUT,
compressing the spring. Piston remains OUT as long
as air line is pressurized.

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Pneumatics 10
10
 Single Acting Cylinder

When air line is exhausted, return spring moves the

piston IN.
Piston will continue to remain IN as long as air line is
exhausted.

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Pneumatics 11
11
 Thus a Single acting cylinder can develop useful
thrust or move objects during OUT stroke.
Return spring generates IN stroke of piston. Force of
return spring is enough to overcome body-piston
friction only and cannot move loads.

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Pneumatics 12
12
 Single Acting Cylinder animated.

Click on the picture to start and stop animation

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Pneumatics 13
13
 Double Acting Cylinder

Body Piston Piston Rod

Airline A Airline B
Airlines through direction control valve are
connected to these.

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Pneumatics 14
14
 Double Acting Cylinder

A B

When line B is pressurized and A is

exhausted, piston remains IN.

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Pneumatics 15
15
 Double Acting Cylinder

A B

When line A is pressurized and B is

exhausted, piston moves OUT.

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Pneumatics 16
16
Double Acting Cylinder animated.

Click on the picture to start and stop animation

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Pneumatics 17
17
 Cylinder Force Calculation

Dia D

The thrust developed by piston rod under static

conditions for OUTWARDS stroke is -
D2
Thrust F (kgs) = X P
4
D is piston dia in cms
P is gauge pressure of air in kgs/ cm2

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Pneumatics 18
18
 Cylinder Force Calculation

Dia D

Example : Cylinder dia 40 mm,

Air Pressure – 5 bar gauge

Thrust = (3.14 x 16 x 5) / 4 = 62.8 kgs

Note thrust is under static conditions

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Pneumatics 19
19
 Cylinder Force Calculation

Piston rod dia d

Dia D

The thrust developed by piston rod under static

conditions for INWARDS stroke is -
(D2 - d2)
Thrust F (kgs) = X P
4
D is piston dia in cm
d is piston rod dia in mm
P is gauge pressure of air in kgs/ cm2

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Pneumatics 20
20
Cylinder Force Calculation

For a Single Acting Cylinder – the static thrust when

piston moves OUT is reduced by spring force
(depending on spring design)
Piston moves IN under spring force.

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Pneumatics 21
21
Cylinder Force Calculation
Under dynamic conditions, cylinders can generate only 60% of
static load

A Double Acting Cylinder dia 40 mm, at 5 kg/cm 2 gauge

pressure can develop a static thrust of 62.8 kgs. (Example
given earlier)

The cylinder can move a load of -

62.8 kgs x 60% = 37.7 kgs only.

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Pneumatics 22
22
Cylinder – End Cushioning

To avoid impact at the end of stroke, larger bore cylinders

are provided with a feature to restrict the speed at the end of
stroke. It is called End Cushioning.

Click on the picture to start and stop animation.

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Pneumatics 23
23
Cylinder – Mountings

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Pneumatics 24
24
 Direction Control Valves

We have seen that a single acting cylinder

needs air line alternately pressurized and
exhausted in order that the cylinder operates.
Direction Control Valves are Control Devices
in a Pneumatic circuit that pressurize and
exhaust air lines as desired.

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Pneumatics 25
25
 Direction Control Valves

P S
This is symbol of a 3 port 2 position,
Normally Closed Valve
Actuation by Hand Knob
Return by Spring
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Pneumatics 26
26
 Direction Control Valves

P S

3 ports are marked P, S and A

This means on the valve, we will find 3 threaded
ports.
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Pneumatics 27
27
 Direction Control Valves
Box 2
Box 1
A

P S

2 position means the valve can remain in 2 states. One

state when box 1 is operative. The other state is when
box 2 is operative.
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Pneumatics 28
28
 Direction Control Valves
Box 1
A

P S

When Box 1 is operative, that is valve is in position 1,

ports are connected as below –
P is closed. A is connected to S.
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Pneumatics 29
29
 Direction Control Valves
Box 2
A

P S

When Box 2 is operative, that is valve is in position 2,

ports are connected as below –
P is connected to A. S is closed.
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Pneumatics 30
30
 Direction Control Valves
A

P S

The ports are marked by letters as below –

P is Pressure port. Connected to supply.
A, B are System ports connected to devices
R,S,T are Exhaust ports connected to silencers.

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Pneumatics 31
31
 Direction Control Valves
Box 2
Box 1
A

Hand
Knob Spring

P S

Actuation by Hand Knob, Return by Spring means –

When hand knob is pressed – Box 2 is operative
When hand knob is not pressed – Box 1 is operative because of the
Spring.

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Pneumatics 32
32
 Direction Control Valves
Box 1
A

P S

Thus the valve has got a tendency to remain with Box 1 operative
whenever knob is not pressed. That is Normal position of valve.
Since port P is closed in that position, it is called Normally Closed
Valve.

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Pneumatics 33
33
 Direction Control Valves

There is a wide variety of

Operating and Return Mechanisms
to suit various requirements.

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Pneumatics 34
34
 Direction Control Valves

P S

Hand Lever Actuated, Spring Return

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Pneumatics 35
35
 Direction Control Valves

P S

Hand Lever Actuated. Hand Lever Return.

No Normal position.

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Pneumatics 36
36
 Direction Control Valves

P S

Cam Actuated, Spring Return

Normally Closed.

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Pneumatics 37
37
 Direction Control Valves

P S
There is an additional port X on the valve body. When X is
connected to compressed air, valve is actuated. When X
is exhausted, valve comes back to its Normal position.
Called Pilot Actuated Spring Return Valve.

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Pneumatics 38
38
 Direction Control Valves
Box 2
Box 1
A

X Y

P S
Pilot Actuated Pilot Return.
When Y is pressurized and X is exhausted
Box 1 is operative.
When X is pressurized and Y is
exhausted, Box 2 is operative.

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Pneumatics 39
39
 Direction Control Valves

X Y

P S
Pilot Actuated Pilot Return.
Since there is no return spring, this valve
has no Normal position.
When both X and Y are exhausted, valve
remains in earlier position.

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Pneumatics 40
40
 Direction Control Valves

X Y

P S

The valve has no defined behavior if both X and Y are

pressurized. Care must be taken in designing the circuit
that both X and Y are not pressurized at the same time.

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Pneumatics 41
41
 Direction Control Valves

X Y

P S

Pilot ports are marked by letters X, Y & Z.

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Pneumatics 42
42
 Direction Control Valves

P S

Actuation by electrical signal. It is called Direct

Solenoid Actuated.
Spring Return

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Pneumatics 43
43
 Direction Control Valves

Sol 1 Sol 2

P S
Solenoid Actuated, Solenoid Return
Direct type.
When both solenoids are OFF, valve remains in earlier
position. There is no Normal position.

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Pneumatics 44
44
 Direction Control Valves

Sol 1 Sol 2

P S
Solenoid Actuated, Solenoid Return
No defined behavior if both solenoids are ON at the
same time. Care must be taken in designing electrical
circuit that this does not happen.

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Pneumatics 45
45
 Direction Control Valves

Solenoid is an electromagnet.
When energized it pulls a part
inside the valve ( a “spool” or a
“poppet”) to operate it.

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Pneumatics 46
46
 To restrict solenoid size and forces, in a solenoid
valve, a common design is to operate the spool
(or poppet) by using compressed air (available
from P port) as a pilot line and solenoid valve
pressurizes or exhausts the pilot line.

Such valve is called Solenoid Actuated with

Internal Pilot.

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Pneumatics 47
47
 Direction Control Valves
Note the arrow meaning internal pilot
A

Sol 1

P S
Solenoid Actuated with Internal Pilot. Spring
Return.
Actually a valve as per above symbol is as
shown on next slide.

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Pneumatics 48
48
 Direction Control Valves
A

P S

T T

Pilot Exhaust
Pilot line

Actual construction of a Solenoid Actuated Internal

Pilot Valve. Spring Return
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Pneumatics 49
49
 Direction Control Valves
A

Sol 1 Sol 2

P S
Solenoid Actuated with Internal Pilot.
Solenoid Return with Internal Pilot
No Normal position.
When both solenoids are OFF, valve
remains in earlier position.
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Pneumatics 50
50
 Direction Control Valves
A

R P

3 port 2 position direction control valve

Normally open
Hand Knob Actuated. Spring Return

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Pneumatics 51
51
 Pneumatic Circuit

3 port 2 pos valve, (Normally

Closed) is used to operate a
Single Acting cylinder.
When knob is not pressed,
cylinder piston remains IN
Supply

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Pneumatics 52
52
 Pneumatic Circuit

When knob is pressed,

cylinder is connected to air
supply. Piston moves OUT
and stays there as long as
Supply knob is pressed.

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Pneumatics 53
53
 Pneumatic Circuit

When the knob is released,

the piston moves IN, air from
cylinder exhausts to
R atmosphere through port R
Supply

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Pneumatics 54
54
 Direction Control Valves

2 port 2 position valve.

Hand knob actuated. Spring Return, Normally Closed
Such valve is used to operate an air jet to clean parts.

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Pneumatics 55
55
 Direction Control Valves
A B

R P S
5 port, 2 position valve
Hand Knob Actuated, Spring Return
This type of valve is used to operate a
Double Acting cylinder
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Pneumatics 56
56
 P Q

A B

When knob is not pressed, piston remains IN.

( If A is connected to Q and B to P, piston will remain OUT)

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Pneumatics 57
57
 P Q

A B

When knob is pressed, piston moves OUT and stays OUT

Air from cylinder front end exhausts thru’ R.

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Pneumatics 58
58
 P Q

A B

When knob is released, piston moves IN.

Air from cylinder back end exhausts thru’ S

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Pneumatics 59
59
 Direction Control Valves – Port Size
 Ports are usually BSP internal threads like 1/8”,
1/4”, 3/8”, 1/2” etc
 For similarly designed valves the amount of air
flow through the valve usually increases with
the port size.
 Port size alone however cannot be relied upon
to give a standard value of flow as this is
dependent on the design of the orifice size.

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Pneumatics 60
60
 Direction Control Valves – Port Size

R3/8
R1/2
R /8
1

R1/4

R1 R3/4

BSP Thread Sizes

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Pneumatics 61
61
 Direction Control Valves – Materials

Manufacturers offer valves in various materials.

For selection, general guidelines are –

Clean, dry conditions – Aluminum

Moist conditions – Brass
Hazardous conditions – Stainless Steel

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Pneumatics 62
62
 Direction Control Valves – Construction

DC valves - Spool and Poppet Type

DC Valves

Spool Type Poppet Type

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Pneumatics 63
63
 Direction Control Valves – Spool Type

X Y

P S

A spool valve as above that is 3 port, 2 pos

Pilot Actuated, Pilot Return will be as in the
next slide ….

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Pneumatics 64
64
Working of a Spool Valve
X is pressurized A Y is exhausted

X Y

P is closed P S A exhausts thru’ S

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65
 Working of a Spool Valve

X is exhausted A Y is pressurized

X Y

P is connected P S S is closed
to A
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66
 Direction Control Valves – Poppet Type

A
X

A Poppet valve as above that is 2 port, 2

pos Pilot Actuated, Spring Return will be
as shown in the next slide.

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Pneumatics 67
67
Working of a Poppet Valve X

When pilot port X is

exhausted – P A
Port P is closed.
Port A is closed.

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Pneumatics 68
68
Working of a Poppet Valve X

When pilot port X is

pressurized – P A
Port P is connected to
Port A.

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Pneumatics 69
69
 Specification of a DC Valve
 No of ports
 No of Positions
 Actuating Mechanism –pilot, solenoid, lever etc
 Return Mechanism – pilot, solenoid, spring etc
 Normally Open or Closed – if applicable
 Port Size – ¼”, ½” etc
 Operating Pressure
 Body Material – Brass, Stainless Steel etc
 Solenoid Voltage and Current – 24V DC
 Any Other – flameproof coil, manual override etc
 Supplier’s catalogue number

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Pneumatics 70
70
Flow Control Valves (Throttle Valves)
Flow Control Valves are used to control speed of
Cylinders during movement.

Free Flow
Regulated Flow

Flow Control Valves allow Free flow in one direction and give
Regulated Flow (which is adjustable) in the other direction.

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Pneumatics 71
71
 Flow Control Valves

Free Flow

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Pneumatics 72
72
 Flow Control Valves
Knob for adjustment

Regulated Flow

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Pneumatics 73
73
 Flow Control Valves

Valve Q regulates OUT movement

of the piston.
P Q
Valve P regulates IN movement of
the piston.

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Pneumatics 74
74
Other Pneumatic Components

Silencer

FRL Unit

Pressure Switch

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Pneumatics 75
75
 Advantages of Pneumatics

Fast : Working speeds up to 1m/sec

Reciprocating Motions are readily available
Stroke setting is possible
Overload safety
Standard parts
Easily transportable
Ease of storage

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Pneumatics 76
76
 Pneumatic Circuits

Press valve P.
Piston will move OUT.

Release P. Press Q.
Piston will move IN.
P Q

Release Q.
Piston will continue to remain IN.

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77
Pneumatic Circuits

When P is released, piston is IN M

Press P. Piston moves out. N

Speed regulated by M.
P
Release P. Piston moves IN
Speed is regulated by N.

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Pneumatics 78
78
 Pneumatic Circuits

Press and release M.

Piston moves OUT. P Q
Speed regulated by Q.
Piston stays OUT.

Press and release N.

Piston moves IN.
Speed regulated by P. M N
Piston stays IN.
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Pneumatics 79
79
 Pneumatic Circuits
N

Press and release M.

Piston moves OUT. P Q
Speed regulated by Q.
At end of stroke, piston
presses N.

Piston moves IN.

Speed regulated by P. M N
Piston stays IN.
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Pneumatics 80
80
 Pneumatic Circuits – Building & Maintenance

 Use piping of at least same size as cylinder or valve

ports. That is use 1/4” pipe for valve or cylinder with
1/4” threads. Do not use reducers and 1/8” pipes.
 Avoid bending load on cylinder pistons.
 Use clean and dry air.
 Protect cylinder piston rod from dirt, dust, coolant.
 Use standard seal kits for repairs.
 Protect parts from mechanical damage.

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Pneumatics 81
81
 Conserve Compressed Air

Compressed air is very costly.

One leak of dia 3 mm may equal
many (say 40) lamps of 60W
capacity

Leakage
=

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Pneumatics 82
82
 Strategies to conserve air –

 Plug all leakages.

 If a device can work at less than line pressure,
use reduced pressure.
 Use single acting cylinders wherever possible.
 Do not use cylinders with excessive strokes.
 Conduct audit of compressed air.

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Pneumatics 83
83
Exercise - A

Work out static and dynamic thrust of

Double Acting Cylinder – Piston dia 32 mm. Piston rod d
Pressure 4 kg/cm2 gauge.

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Pneumatics 84
84
Exercise - B

Describe the following valve -

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Pneumatics 85
85
Assignment A
a0 a1
B
b0 b1

b0 b1 a1 a0

Work in a group. Analyze the circuit and

describe how it will function.
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86
 Summary
Pneumatics is a vast subject. Designing, Operating
and Maintaining Pneumatic Circuits needs
conceptual as well as practical skills. Handled
properly, they can work reliably and efficiently.

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Pneumatics 87
87
 Let us commit ourselves to
get the most out of our
Pneumatic Systems to boost
Productivity.

Click on the picture to start and

stop animation.
07-05-05 JH Step 4 - Pneumatics 88
Pneumatics 88
88
 For feedback / other Training Packs and
Training Programs tailored to your specific
needs, please contact -
G.V.Khare,
Star Enterprises, “Saikripa”, Behind ALCO Market,
Rajivnagar, Nashik – 422 009
Tel – (0253) – 2394252, Mobile – 98233 71900
Email – [email protected]

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89
 End of Presentation

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