Unit III

AUTOMATION USING PNEUMATIC SYSTEMS

Pneumatic Fundamentals

A system that uses compressed air for transmitting and controlling energy in various
industries is known as a Pneumatic system. These systems mainly work by using a constant
compressed air supply which is provided by an air compressor. The compressor takes the air from
the atmosphere & stores it in a receiver which is known as a high-pressure tank. After that, this
compressed air is supplied to the system through a series of valves or pipes.

Pneumatic System Construction:

Pneumatic system components mainly include

o Intake Filter
An intake filter is used to filter out the pollutants from the air which is also known as an air
filter.
o Compressor
The main function of this compressor is to reduce the volume of air & increase the air pressure.
o Motor Control Center
The motor in this system is used to supply mechanical energy to the compressor because the
motor function is to change the energy from electrical to mechanical.
o Cooler
The cooler is used to decrease the temperature of the compressed air.
o Separator
The separator is used to separate the moisture or water vapor within the air.
o Receiver
The receiver in the system is a high-pressure tank, used to store the compressed air which is
coming from the air coolers.
o Air Treatment
 The air treatment in the above system can be separated into three stages. So, in the first stage,
the large size particles are banned from entering the compressor through an intake filter. The air
exiting from the compressor may have a high temperature, so it is treated in the next stage. In the final
stage, the compressed air temperature is decreased with a cooler & the compressed air can be dried
through a dryer.
o Pressure Switch
Pressure switches in the above system are used to detect the increase or decrease in air
pressure which are either changeable or not adjustable. These switches are used in vacuum or pressure
applications.
o Control Valve
The control valve in the above system is used to change the airflow direction.
o Air Actuator
In a pneumatic system, the air actuator is an essential part and the main function of this is to
use the compressed air energy which is also called pressure energy & change it into mechanical
energy. So we can get the final output from the air actuator.

Pneumatic System Working Principle

o At first, the air is taken directly from the atmosphere by using the air filter. This air is cleaned &
purified within the air filter.
o These filters are essential because if the air is used directly from the atmosphere, it can damage the
compressor. After that, the air can be supplied to the air compressor which is driven by the
mechanical energy produced by the electric motor.
o The air compressor increases the air pressure & decreases its volume. When the air pressure is
increased, then its temperature can also be increased.
o Thus in the next step, compressed air is transmitted to the air coolers which reduces its
temperature but its pressure will remain the same even after reducing its temperature.
o After that, the air which is cooled is transmitted and stored within the receiver tanks. After that,
this air can be transmitted to the air treatment chamber which is also known as filter regulator
lubricator or FRL Once the air is moved into this chamber, then it is dried.
o In a pneumatic system, this process is very important because the components used in the
pneumatic system are delicate. If this air treatment is not used then the air might be wet & warm
and it is transmitted directly to the receiver tank So, this will have a the serious impact on the
remaining parts. So by using this, the system performance and efficiency can be increased.
o The air from the air treatment is transmitted to the control valve to change the flow direction based
on the requirements. Finally, the air actuator uses the energy of air and converts it into mechanical,
thus we can get the final output from this actuator.
 Control Elements
Control elements are essential for directing and managing the flow of compressed air within a
pneumatic system. They include:
Valves:
Air control valves are used to control the pressure, flow rate, and direction of air in pneumatic
circuits. Pneumatic pressure control valves are air line regulators that are installed at the inlet of
each separate pneumatic circuit. As such, they establish the working pressure of the particular
circuit.
These are the primary control elements in pneumatic systems. They regulate the direction,
pressure, and flow of the compressed air. A pneumatic valve is characterized by a number of
connections (ports) and a number of switching positions.
Basic Components of a Pneumatic Valve
o Inlet Port (P): The point where compressed air enters the valve.
o Outlet Ports (A, B, etc.): The points where air is directed to the actuator or other parts of the
system.
o Exhaust Ports (R, S, etc.): The points where air is released after performing work.
o Spool or Poppet: The internal mechanism that opens and closes the flow paths within the valve.
o Actuation Mechanism: The method used to move the spool or poppet. It can be mechanical,
manual, solenoid (electrically actuated), or pneumatic.

Working Principle:
The operation of a pneumatic valve can be understood through the example of a 4/2 directional
control valve. This type of valve has four ports and two positions. The basic principle is as follows:
o Initial Position (Resting State):
In its default state, the spool or poppet is positioned to block certain ports and allow air to flow
through others. Compressed air enters through the inlet port (P) and is directed towards one of the
outlet ports (A) while the other outlet port (B) is connected to the exhaust port (R).
o Actuation (Switching State):
When the actuation mechanism (e.g., a solenoid) is activated, it shifts the spool or poppet to a
different position. This new position changes the flow path of the air, now directing it from the inlet
port (P) to the other outlet port (B) and exhausting the air from port A through port S.
o Return to Initial Position:
Once the actuation mechanism is deactivated, the valve returns to its initial position either
through a spring return mechanism or a signal from a pneumatic pilot. This operation allows the
control of actuators in a pneumatic system by determining which side of a cylinder receives air,
thereby controlling the direction of movement.
3/2 valve:
A 3/2 valve has three ports for supply (1), output (2) and exhausting (3) respectively,
combined with two switching positions. As only one working output is available, this valve can only
fill one chamber with compressed air.

This means that the cylinder is single acting and the return stroke must be achieved mechanically,
e.g. with a spring assembly.

5/2 valve:

A 5/2 valve also has two switching positions but provides two additional ports for working (4) and
venting (5). With this, two chambers can be pressurized and exhausted which means full control of
both sides of the actuator. With a 5/2 valve, a movement can therefore be fully pneumatic.

Actuators:
A pneumatic actuator definition is a type of actuator used to change the energy which is in
the compressed air form to motion. There are different forms of pneumatic actuators where some
actuators convert the energy of compressed air into linear motion & some actuators changes to rotary
motion.

These actuators have different names in the industry like air cylinders, air actuators &
pneumatic cylinders.

Working of a Pneumatic Actuator:

A Pneumatic actuator mainly depends on some form of pressurized gas like compressed air
which enters into a chamber to build up pressure. Once this air builds up sufficient pressure as
compared to the external atmospheric pressure, then it results in the controlled kinetic movement of a
device like a gear or a piston. So this resulting movement is directed in either a circular motion or in a
straight line. These actuators are one of the most frequently used mechanical devices in a wide range
of current industries when compressed gas is converted into energy is extremely controlled and
repeatable and reliable.
Pneumatic Actuator Construction:

The pneumatic actuator is constructed by using different components like a spring,

compressor, reservoir, diaphragm, and valve. The following diagram represents the construction of a
pneumatic actuator. To drive this system, the energy of the fluid is changed to mechanical. In this
system, the fresh air is compressed through the compressor & this air is simply stored within the
storage reservoir.

When air supply pressure is increased, the diaphragm moves continuously in the down
direction & this closes the control valve totally at a particular point. Similarly, once air supply
pressure is decreased, then the applied force on the diaphragm by the spring overcomes the force
because of the supplied force. This can cause motion in the up direction of the diaphragm to open the
control valve.

Here, it is also noted here that the control valve’s position mainly depends on the pressure of
air. As a result, the control valve opening & closing is related to the diaphragm’s movement with the
pressure of air.

Position Sensing in Pneumatic Systems

Position sensing in pneumatic systems is crucial for determining and controlling the position
of actuators (such as cylinders) during operation. This is important for ensuring that the actuators
move to the correct positions, which is essential for process accuracy and safety.

Common Position Sensing Methods

1) Limit Switches:

Function: Detect the physical position of an actuator by making direct contact with it.
Operation: When the actuator reaches a certain position, it physically contacts the limit switch, which
then sends an electrical signal to indicate the position.
Use: Used in applications where precise, end-of-stroke detection is necessary, such as in packaging or
assembly machines.

2) Proximity Sensors:

Pneumatic proximity sensors operate on the basis of changes in air pressure. When an object
approaches the sensor, it causes a change in the air pressure within a specific sensing area. This
change is then detected by the sensor, which sends an electrical signal to a control system to indicate
the presence or absence of the object.
o Inductive Sensors:
v Detect the presence of metallic objects without physical contact.
v The sensor generates an electromagnetic field. When a metal object enters this field, it
disturbs the field, triggering the sensor.
v Use: Ideal for detecting the position of metal components in a pneumatic actuator.
o Magnetic Reed Switches:
v Detect the position of a magnet attached to the piston inside a pneumatic cylinder.
v The reed switch closes its contacts when the magnetic field from the magnet on the piston
is detected.
v Common in pneumatic cylinders where precise piston position detection is needed.
o Linear Potentiometers:
v Provide a continuous variable resistance corresponding to the position of the actuator.
v A wiper moves along a resistive track as the actuator moves, changing the resistance and
providing a signal proportional to the position.
v Used in applications requiring continuous position feedback, such as in precision control
systems.

Common Pressure Sensing Devices

1) Pressure Gauges:
o Function: Provide a visual indication of the pressure within a pneumatic system.
 o Operation: A dial with a needle indicates the pressure, typically measured in PSI (pounds per
square inch) or bar.
o Use: Used for manual monitoring and adjustment of pressure in pneumatic systems.

2) Pressure Switches:
A pressure switch is used to control an electrical circuit based on the pressure within a system,
activating or deactivating the circuit when a preset pressure level is reached.
o Function: Activate or deactivate a circuit when a specific pressure level is reached.
o Operation: When the system pressure reaches a predetermined set point, the pressure switch
closes or opens an electrical contact, triggering a response (e.g., stopping a compressor or
signaling an alarm).
o Use: Commonly used as safety devices to protect systems from overpressure or under pressure
conditions.
3) Pressure Transducers and Transmitters:
o Function: Convert pressure into an electrical signal for monitoring and control purposes.
o Operation: The transducer generates a signal (typically 4-20 mA or 0-10 V) proportional to the
pressure level. This signal can be read by a controller or monitoring system.
o Use: Essential in automated systems where continuous pressure monitoring is required for
process control.
4) Manometers:

o Function: Measure the pressure difference between two points in a system, typically using a
column of liquid (such as water or mercury).
o Operation: The difference in liquid levels in the manometer indicates the pressure difference
between the two points.
o Use: Used for calibrating and checking system pressure, often in laboratory or testing
environments.
 PNEUMATIC CIRCUIT DESIGN CONSIDERATIONS
When analyzing or designing a pneumatic circuit, the following four important considerations
must be taken into account:
1. Safety of operation
Safety of operation means that an operator must be protected by the use of built-in emergency
stop features as well as safety interlock provisions that prevent unsafe, improper operation. Although
compressed air is often quiet, it can cause sudden movements of machine components. These
movements could injure a technician who, while troubleshooting a circuit, inadvertently opens a flow
control valve that controls the movement of the actuator.

2. Performance of desired function

Performance of the desired function must be accomplished on a repeatable basis. Thus, the
system must be relatively insensitive to adverse conditions such as high ambient temperatures,
humidity, and dust. Shutting down a pneumatic system due to failure or misoperation can result in the
stoppage of a production line. Stoppage can result in very large costs, especially if the downtime is
long because of difficulty in repairing the pneumatic system involved.

3. Efficiency of operation
Efficiency of operation and costs are related design parameters. A low-efficiency compressor
requires more electrical power to operate, which increases the system operating costs. Although
atmospheric air is “free,” compressed air is not. Yet if a pneumatic system leaks air into the
atmosphere without making significant noise, it is often ignored, because the air is clean. On the other
hand, a hydraulic leak would be fixed immediately, because it is messy and represents a safety hazard
to personnel in the vicinity of the leak.

4. Cost
Pneumatic circuit air losses through various leakage areas with a combined area of a 0.25-in-
diameter hole would equal about 70 scfm for an operating pressure of 100 psig. Examples of such
leakage areas include the imperfect sealing surfaces of improperly installed pipe fittings. A typical
cost of compressing air to 100 psig is about $0.35 per 1000 ft3 of standard air. Therefore, it costs
about $0.35 to compress 1000 ft3 of air from 14.7 psig to 100 psig. Thus, the yearly cost of such a
leaking pneumatic system operating without any downtime is $12,900/yr
 DESIGN CALCULATIONS
AIR PRESSURE LOSSES IN PIPELINES
As in the case for liquids, when air flows through a pipe, it loses energy due to friction. The
energy loss shows up as a pressure loss, which can be calculated using the Harris formula:

where
pf = pressure loss (psi),
c = experimentally determined coefficient,
L = length of pipe (ft),
Q = flow rate (scfm),
CR = compression ratio = pressure in pipe/atmospheric pressure,
d = inside diameter of pipe (in).
For schedule 40 commercial pipe, the experimentally determined coefficient can be
represented as a function of the pipe inside diameter:

Substituting above equation into the Harris formula yields a single usable equation for
calculating pressure drops in air pipelines

BASIC PNEUMATIC CIRCUTS

AND GATE:

Passive AND Element Active AND Element

 An AND element must receive two input signals simultaneously before it passes an output
signal. This ensures that two upstream functions are complete before there is a command to a
downstream function. In other words, inputs A and B must both be present before an output action
occurs.
When using more than two inputs, AND elements are connected in series. The first AND
receives signals 1 and 2, and the output of this element interfaces with an input to the second AND.
The other input of the second AND receives a third signal, making three inputs necessary before an
output action can occur.
Figures 1 and 2 show two types of AND elements. Some manufacturers supply passive and
active types of elements but designate the passive AND simply AND, whereas the active AND is
designated YES. The difference in the elements is that the passive AND element uses the lower of the
two inlet ports as an output. In contrast, the active AND element has two inputs to achieve an output,
but the designer has the choice of which input goes to the output. Using this feature can amplify a
weak signal. The weak signal pilots the valve open while the through signal comes from a full-
pressure supply. The YES is an active element.

OR ELEMENT

A signal at either input port of an OR element produces an output signal. Another way of
saying this is that either signal A or B will produce an output. A shuttle valve serves the same purpose
as an OR element. Pilot signals from two different sources can pass through the OR to start the next
function. An OR element differs from an in-line tee because an OR passes either input to the output
but does not allow the inputs to pass to each other. OR elements can be stacked to accommodate more
than two inputs. Use an extra OR for each input after the first two signals.

NOT ELEMENT
A NOT logic element is a normally open 3-way valve. An input signal to the Supply port will
pass through the valve until there is a pilot signal at port A. Pressurizing port A blocks supply and
exhausts the output signal to atmosphere through port B. As long as there is pilot pressure on the A
port, NOT elements will block a signal or supply. NOT elements always return to a normally open
condition when the pilot signal is removed.

A NOT element can simulate a limit switch to indicate that a cylinder is at the end of stroke.
Pressure from the cylinder port goes to port A of the NOT, holding it closed. As the cylinder extends
toward the work, pressure is maintained because of the meter-out flow control. When the cylinder
contacts the work, the signal at port A exhausts, and the NOT opens to pass an output signal to start
the next operation.

FLIP FLOP

A FLIP FLOP is a double-piloted 5-way valve that directs supply air to either outlet port in
response to signals at pilot ports S or R. (Supply air can be system pressure or a signal from another
logic element.) The main purpose of a FLIP FLOP is to exhaust the first pilot signal to a directional
control valve. Then a second signal to the valve’s opposite pilot port can shift it back. FLIP FLOPs are
sometimes called MEMORY elements because they stay in the last shifted position even with no air
supply. Whether the signal is maintained or drops out, output from the FLIP FLOP stays the same.
The S and R signal designations stand for SET and RESET. The SET signal shifts the FLIP
FLOP for a function, and whether S is maintained or not, the element stays shifted. The RESET signal
returns the FLIP FLOP to its original position until the next cycle.
 FAULT FINDING IN PNEUMATIC SYSTEMS
Pneumatic systems are utilized everywhere today. From reliability and energy efficiency, these
systems offer many advantages, and their ease of use and versatility enables complex tasks to be
completed more quickly than other power tools. Luckily, many of the most common issues in
pneumatic systems have simple fixes.

1. Operating Pressure Issues

Good air pressure is essential for a well-powered pneumatic system. Air pressure issues are a
significant contributor to system issues and can be caused by several things. While many times the
source of air pressure loss is rooted in the compressor, leaky valves and connections, dirty filters, and
poor maintenance habits can all play a part. Operating over the product’s pressure range, on the other
hand, is often due to unidentified leaks and poor pressure control and will cause a system to
malfunction. But any pressure issues—too low or too high—will impact the system's overall
efficiency and operating costs.
Here's what to look for and how to fix operating pressure issues impacting your system:
o Inconsistent (or no) airflow—the occurrence of pressure issues can happen in the intake filter.
If the filter is damaged or corroded, the intake becomes plugged. To fix this, simply remove
and either clean or replace the intake filter.
o Underpowered or machine not working—when the system is underpowered, it’s most likely
because you have a leak somewhere. The best way to find leaks is by using an aerosol sprayer
that can be filled with soapy water or light oil. Spray one end of the hose, so the liquid makes
its way down through its length; if there are leaks in hoses or attachments, bubbles will appear
where they connect (bubbles mean air escaping). Fixing these leaks requires tightening fittings
with adjustable wrenches until they no longer leak.
o The equipment is malfunctioning—a malfunctioning component could stop working altogether
if there isn't enough pressure running through its wires and pipes (or it might work
intermittently). To locate the source/component causing the supply issue, check to see if your
compressors are working correctly. If there’s no obvious source of lost pressure, the most
likely cause is the pump(s) driving the pneumatics, and you’ll need to either repair or replace
those components.

2. Voltage and Power Issues

It may seem obvious, but when your pneumatic system throws errors, the power source, power
connections, and improper voltage usage could be causing the issue. Without a stable voltage, or if the
voltage is over or under the operating range, the system will not operate smoothly and may be
damaged. Important note: when assessing voltage or power concerns, ensure that the power is turned
off and that there is no air flowing through the machine.
o Inconsistent or unsmooth operation check the machine’s operating specifications to ensure
you’re utilizing the correct voltage. Also, a compressor can get bogged down when it splits the
power supply with other devices. Air compressors need their own power supply, which leads
to a breaker with the system’s specified requirements.
o The compressor blows fuses or breakers - the motor could be deprived of sufficient energy,
causing the motor to overheat. Make sure to connect your system directly to a power source
and that you are using both the correct power and voltage requirements.
o The machine isn’t working—if it is plugged in, a poor connection may explain why it isn’t
working. Make sure that no water or other liquids have shorted out cables and that they aren’t
damaged or obstructed in any way.

3. Environmental Issues
Whether working in areas of extreme temperatures or in a facility that processes chemicals,
environmental factors can have catastrophic impacts on pneumatic systems. Significant temperature
changes can have physical effects on the machine. At the same time, any external particulate exposure
can lead to the introduction of contamination into the system. But regardless of the cause,
environmental issues can have lasting effects on the system as a whole.
o Deformation and misalignment—when metal is subjected to high heat, it expands, and
contracts in reduced temperatures. The expanding-contracting cycle of metal components can
result in parts becoming deformed or misaligned, impacting the system's overall efficiency. To
avoid these issues, be sure not to leave your compressor exposed to extreme temperature
fluctuations and be aware of the ambient temperatures when working with your system.
o Excessive pressure on the system—microscopic particulates such as dust can build up inside
the system, reducing the amount of space that air can expand and creating intense pressure on
the system. One way to identify contamination issues is if you notice bubbles forming at
connections between pieces of equipment, such as couplers or quick disconnects (QDs). This
occurs because some types of contaminants don’t easily mix with gas molecules and will form
their own pockets within hoses or piping—a process called stratification. Cleaning, regular
maintenance, and quality insulation can help prevent microscopic particulates from affecting
your system.

4. Mounting Issues
No matter how good your pneumatic system is, poor mounting will hasten premature system
failure. Improper mounting can lead to side loading, which occurs when a load is placed on the piston
rod without guidance or support or when the mounting and piston rod connection is misaligned. Once
side loading occurs, for example, pneumatic cylinder repairs will be necessary. While there are several
ways to mitigate side loads, nothing can take the place of proper, precise alignment during initial
installation.

5. Poor Air Quality Issues

Air quality impacts the demand side of components such as pressure valves, flow control
valves, and linear or rotary actuators. Poor air quality on these components can have a waterfall effect
on the entire system. Often, the causes of poor air quality issues in pneumatic systems are moisture
and particulates, which can make their way into the system via airflow and lead to systemwide
damages that may result in unexpected failures.
o Severe corrosion visible on the pistons— Moisture can enter a system through several places
and wreak havoc on a pneumatic system. Prolonged moisture exposure leads to corrosion
which then gets dislodged and works through other components in the system, causing a
multitude of problems throughout the system - need to get a filter specifically designed to
mitigate moisture from entering the system.
o Scoring on the piston rods and poor sealing—just like moisture, particulates can enter the
system in a number of ways, such as through dirty filters, and can become lodged into seals
and act like emery cloth on rods and barrels, causing severe scoring, leaks, poor sealing, and
premature failures. As with moisture, to avoid particulates entering your system, replacing
filter should be the first act.
o Valve spool jamming—it’s one of the most common problems in pneumatic systems and is
usually caused by debris or corrosion in the system, which can cause a valve to stick and not
open properly. Avoid valve spool jamming by replacing dirty filters and performing regular
maintenance on your machine.

6. Wrong product selection

Even though pneumatic systems are simple in design, easy to install, economical in price, and
durable when it comes to performance, selecting the right pneumatic system for your specific
application can be challenging. From choosing the correct directional force required to determining
the load requirements for your particular process, it’s not hard to miss the mark on product selection.
 HYDRO PNEUMATIC CIRCUITS
Hydro pneumatic circuits combine the advantages of both hydraulic and pneumatic systems,
using air as a working medium for quick motion and hydraulic fluid for precise control and force
application. These systems are commonly used in applications where both speed and power are
required.
o Hydraulics: Uses incompressible fluid (oil) to transmit power. Provides high force and
precision.
o Pneumatics: Uses compressed air to transmit power. It is lightweight and faster but provides
less force.
Key Characteristics:
o Combination of Speed and Force: Pneumatics offers speed, while hydraulics provides force.
o Compact Design: Hydro-pneumatic systems are often more compact and require fewer
components than purely hydraulic systems.
o Energy Efficiency: These systems optimize the use of energy by using compressed air for
rapid movement and hydraulic oil for controlled force.

Components of Hydro Pneumatic Circuits

Hydro pneumatic systems consist of the following key components:
o Compressor: Provides compressed air for the pneumatic system.
o Air Treatment Unit: Ensures clean, dry, and regulated air supply. It includes filters, regulators,
and lubricators.
o Hydraulic Pump: Supplies pressurized hydraulic fluid to the system.
o Hydro-Pneumatic Cylinder: A combination of a pneumatic cylinder and a hydraulic cylinder
to deliver quick movement with high force.
o Pressure Accumulators: Stores pressurized fluid for quick release, ensuring the system can
react quickly.
o Control Valves: Directs the flow of both compressed air and hydraulic fluid. Includes
directional control valves, pressure relief valves, and flow control valves.
o Sensors and Actuators: These are used to monitor and control the system’s actions.

Design and Working Principles

A hydro pneumatic circuit is designed to take advantage of both the high-speed capabilities of
pneumatics and the high-force capabilities of hydraulics.
1. Pneumatic Stage:
a. Initially, compressed air moves the actuator quickly into position.
b. Directional control valves manage the airflow.
 2. Hydraulic Stage:
a. Once the pneumatic stage completes, the hydraulic system takes over for fine
positioning or applying a heavy load.
b. Hydraulic pressure intensifies the force output of the system.

Working of a Hydro-Pneumatic Circuit:

o Rapid Movement Stage: The pneumatic cylinder is activated, moving the load rapidly toward
its final position.
o High Force Stage: The hydraulic cylinder engages, providing precise control and high force
to complete the task.
This dual-phase operation allows for both speed and precision, ideal for systems where high
throughput and accuracy are needed, such as stamping presses or automated production lines.

Example of Hydro Pneumatic Circuit

Circuit for Press Application:
o Pneumatic Section: The pneumatic section moves the press ram quickly to its working
position. A double-acting pneumatic cylinder is used for rapid advance and return of the ram.
o Hydraulic Section: The hydraulic section generates the necessary pressing force once the
pneumatic cylinder has brought the press ram to its working position. A hydraulic intensifier
or separate hydraulic cylinder provides the required force for pressing.
Control Elements:
o Directional Control Valve (Pneumatic): Directs the compressed air to move the ram.
o Pressure Relief Valve (Hydraulic): Ensures the hydraulic pressure doesn't exceed safe limits.
o Flow Control Valve (Hydraulic): Regulates the speed of hydraulic fluid entering the system for
smooth operation.

5. Applications of Hydro Pneumatic Circuits

o Metal Forming and Stamping: High-speed positioning with pneumatic systems and high-force
pressing with hydraulic systems.
o Injection Molding: Used to quickly move mold halves and apply the necessary clamping force.
o Material Handling: Speedy lifting and precise placement of materials using pneumatic
movement combined with hydraulic control.
o Automotive Industry: Processes requiring a combination of speed and high force, such as
welding and pressing operations.
 ARM CONTROLLER FOR SEQUENTIAL CIRCUITS
The use of an ARM controller for sequential circuits in hydro-pneumatic systems can be
extremely valuable for automating complex tasks that involve multiple steps executed in a particular
order. ARM controllers are microcontrollers based on the ARM architecture, widely used in
embedded systems because of their efficiency and flexibility.

How ARM Controllers are Used in Sequential Circuits:

o Programmable Logic Control:
o ARM controllers can be programmed to control pneumatic and hydraulic actuators in a
predefined sequence.
o Each stage of the sequence can be triggered by sensors or time delays, and the ARM
controller manages these transitions.
o Sensor Integration:
o ARM controllers can read input from sensors (position sensors, pressure sensors) and
use this data to determine the next action in the sequence.
o For example, when a pneumatic cylinder reaches a specific position (detected by a
sensor), the ARM controller can then trigger the hydraulic system to apply force.
o Sequential Timing:
o ARM controllers are equipped with timers that can manage the timing of each step in
the sequence.
o For example, in a hydro-pneumatic press application, the ARM controller can first
trigger the pneumatic system for quick movement, and then after a preset time (or upon
receiving feedback from sensors), activate the hydraulic system to apply the required
force.
o Control of Valves and Actuators:
o ARM controllers send output signals to control valves that manage the air and
hydraulic fluid flow.
o Using GPIO (General-Purpose Input/Output) pins, the controller can activate or
deactivate different valves in a specific order to achieve the desired sequence.
o Multi-tasking and Interrupt Handling:
o ARM controllers can handle multiple tasks simultaneously, such as monitoring
different sensors and controlling various actuators in real-time.
o Interrupts allow the ARM controller to pause a task if certain conditions are met (e.g., a
sensor triggers an event) and switch to the next task in the sequence.
o Feedback Loops:
 o ARM controllers can implement closed-loop control systems, where the output of each
step in the sequence is constantly monitored, and adjustments are made in real-time to
ensure precise control.
o For example, if the pneumatic actuator is moving too quickly or slowly, the controller
can adjust air pressure or flow rates accordingly.

Application Example: ARM-Based Control of Hydro-Pneumatic Press

1. Step 1: Pneumatic Movement Initiation
The ARM controller initiates the pneumatic system to move the press ram quickly
towards the workpiece. This movement is monitored by a position sensor, which sends
feedback to the controller.
2. Step 2: Sensor Feedback and Transition to Hydraulic Force
Once the pneumatic cylinder reaches the desired position (detected by a position
sensor), the ARM controller switches off the pneumatic system and activates the hydraulic
system.
Hydraulic pressure is applied to complete the pressing operation, providing the
required force.
3. Step 3: Completion and Return
After the pressing operation is complete, the ARM controller signals the pneumatic
system to retract the press ram.
4. The system returns to its starting position, ready for the next cycle.

Advantages of Using ARM Controllers for Sequential Circuits:

o Precision Control: ARM controllers provide precise timing and control of each sequential step,
improving overall system accuracy.
o Automation: By using ARM controllers, the entire process can be automated, reducing human
intervention and improving productivity.
o Flexibility: The sequence can be easily reprogrammed for different applications or tasks
without hardware changes.
o Energy Efficiency: ARM controllers can optimize energy use by managing when to engage the
pneumatic and hydraulic systems, ensuring that power is only used when necessary.