PNEUMATICS

CIRCUIT
DEVELOPMENT
AND SIMULATIONS
ENCILA - DIAMANO - GABRIEL - GAPUZ
GARCIA - LABALAN - DEOFERIO - DIZON
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AIR
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PRESSURE
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C_________N
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COMPRESSION
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V_____
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VALVES
PNEUMATIC CONTROL SYSTEMS
Pneumatic control systems are widely used in industrial automation for controlling
machinery using compressed air. Pneumatic circuits are designed to regulate the
movement of actuators like cylinders and motors efficiently. This report provides an
overview of the development of basic pneumatic control circuits, including components,
design principles, and an example circuit.
COMPONENTS OF A PNEUMATIC
CIRCUIT
"Air Supply System"
Compressor: Generates compressed air.
Air Tank (Reservoir): Stores compressed air.
FRL Unit (Filter, Regulator, Lubricator): Ensures clean, regulated,
and lubricated air for smooth operation.
"Actuators" Single-acting cylinder: Uses air to extend and a
spring to retract. Double-acting cylinder: Uses air for both
extension and retraction. Pneumatic motor: Converts air pressure
into rotary motion.
COMPONENTS OF A PNEUMATIC
CIRCUIT
"Control Valves" Directional Control Valves (DCVs): Control the
airflow direction (e.g., 3/2, 4/2, 5/2 valves). Flow Control Valves:
Regulate the speed of actuators. Pressure Control Valves:
Maintain safe and optimal system pressure. "Sensors and
Switches" Limit switches: Detect cylinder position. Proximity
sensors: Sense object presence for automation. Pressure sensors:
Monitor and regulate air pressure.
PNEUMATIC ACTUATORS
Pneumatic actuators convert compressed air
into mechanical motion, which can be linear
(cylinders) or rotary (motors). They are widely
used in automation, robotics, and industrial
applications due to their high speed, reliability,
and simplicity.
TYPES OF PNEUMATIC ACTUATORS
1. Linear Pneumatic Actuators (Cylinders)
These actuators produce straight-line motion and are classified into:
A. Single-Acting Cylinder (SAC)
Uses compressed air to extend the piston.
A spring returns the piston when the air is released.
Advantage: Low air consumption, simple design.
Disadvantage: Limited stroke length due to the return spring.
Example Application: Punching and pressing mechanisms.
B. Double-Acting Cylinder (DAC)
Uses compressed air for both extension and retraction.
Requires a 5/2-way valve for air control.
Advantage: Stronger force in both directions, no need for a spring.
Disadvantage: Uses more air, requires more control components.
Example Application: Robotic arms, conveyor systems.
TYPES OF PNEUMATIC ACTUATORS
C. Telescopic Cylinder
Has multiple stages for long stroke lengths in a compact design.
Can be single-acting or double-acting.
Example Application: Garbage trucks, lifting platforms.
D. Rodless Cylinder
The piston moves inside a sealed tube without an external rod.
Uses magnetic coupling or mechanical linkage.
Advantage: Space-saving design, allows longer strokes.
Example Application: Sliding doors, automated material handling.
TYPES OF PNEUMATIC ACTUATORS
2. Rotary Pneumatic Actuators
These actuators convert compressed air into rotary motion.
A. Pneumatic Vane Motor
Uses air pressure to rotate a vane inside a chamber.
Advantage: Simple design, high speed.
Example Application: Pneumatic drills, grinders.
B. Rack and Pinion Actuator
Uses a piston-driven rack that rotates a pinion gear.
Produces precise angular movement.
Example Application: Industrial robotic arms, valve controls.
C. Scotch Yoke Actuator
Converts linear piston motion into oscillating rotary motion.
Example Application: Large industrial valves.
KEY FACTORS IN SELECTING A
PNEUMATIC ACTUATOR

Required force or torque → Depends on air pressure and load.

Stroke length or rotation angle → Defines movement range.
Speed requirements → Affected by air flow and control valves.
CONTROL VALVES
 CONTROL VALVES
Control valves in a pneumatic control system
are mechanical devices that regulate the flow,
pressure, or direction of compressed air within
the system. These valves play a crucial role in
ensuring precise operation of pneumatic
actuators, cylinders, and other components
 CONTROL VALVES
Functions of Control Valves in Pneumatics
Start/stop airflow to different components.
Control actuator movement (extend, retract,
hold position).
Regulate speed of cylinders or motors.
Protect system from excessive pressure
TYPES OF CONTROL VALVES IN
PNEUMATIC SYSTEMS
1. Directional Control Valves (DCVs) – Direct
the flow of compressed air to different parts
of the system.
Two-way, Two-position (2/2-way valve)
Three-way, Two-position (3/2-way valve)
Four-way, Two-position (4/2-way valve)
TYPES OF CONTROL VALVES IN
PNEUMATIC SYSTEMS
2.Flow Control Valves – Regulate the speed of
actuators by controlling the air volume passing
through.
Throttle Valve
Quick Exhaust Valve
TYPES OF CONTROL VALVES IN
PNEUMATIC SYSTEMS
3.Pressure Control Valves – Maintain or limit
air pressure within a system.
Pressure Relief Valve
Pressure Regulator (Reducing Valve)
Sequence Valve
Pressure Sustaining Valve
TYPES OF CONTROL VALVES IN
PNEUMATIC SYSTEMS
4.Special Control Valves
Time Delay Valve
Proportional Control Valve
Logic Valves (AND, OR Valves)
 PNEUMATICS

PNEUMATIC
INTRODUCTION

SYSTEMS USING
Pneumatic systems play a crucial role in various
industrial applications, including manufacturing,
automation, and material handling. These systems use
compressed air to generate mechanical motion, offering

SIMULATION
advantages such as reliability, simplicity, and cost-
effectiveness. However, designing and optimizing
pneumatic systems require careful analysis to enhance

TOOLS
efficiency and performance.
PNEUMATIC SYSTEMS
FUNDAMENTALS OF USING
SIMULATION TOOLS
PNEUMATIC SYSTEMS

Basic Components

Compressors: Generate and store compressed air.

Valves: Control air flow and pressure.
Actuators: Convert compressed air into mechanical
motion (linear or rotary).
Pipelines and Fittings: Transport compressed air to
different components.
PNEUMATIC SYSTEMS
WORKING PRINCIPLES AND USING
SIMULATION TOOLS
CONTROL MECHANISMS

Advantages and Limitations

Advantages:
High-speed operation and reliability.
Clean and safe for various applications.
Simple design and maintenance.
Limitations:
Energy losses due to air compression and leakage.
Limited force generation compared to hydraulic
systems.
Requires regular maintenance to ensure efficiency.
 PNEUMATIC SYSTEMS
SIMULATION TOOLS FOR USING
SIMULATION TOOLS
PNEUMATIC SYSTEMS

Simulation software allows engineers to design and test pneumatic circuits virtually,
reducing prototyping costs and minimizing design errors.

FluidSIM
Developed for designing and analyzing pneumatic, hydraulic, and electrical
circuits.
Provides a user-friendly interface with animated simulations.
Useful for educational and industrial applications.

Automation Studio
Offers a comprehensive platform for modeling fluid power and electrical
systems.
Includes performance analysis tools for optimizing pneumatic circuits.
Supports real-time control and troubleshooting.
 PNEUMATIC SYSTEMS
SIMULATION VS. REAL- USING
SIMULATION TOOLS
WORLD IMPLEMENTATION

System Selection
A simple pneumatic circuit is analyzed: a double-acting cylinder controlled
by a 5/2-way directional control valve.

Simulation Setup
The circuit is modeled using FluidSIM.
Parameters such as actuator stroke time, pressure levels, and air flow rate are
measured.
Real-World Testing
A physical prototype is built using industrial components.
Measurements are taken to compare with simulated values.
 PNEUMATICS

BISTABLE
INTRODUCTION

These valves can be used in energy saving

VALVE circuits For example, if being powered by a

battery or if heat generation from a

CONTROL
solenoid will cause an issue as the solenoid
is energized for short periods only, minimal
heat is generated from them.
 PNEUMATICS

BISTABLE
INTRODUCTION

Bistable valves are a type of directional control

valve which have two stable positions. Power is

VALVE only needed while they are changing between

states. The valve spool will remain in place when it
is triggered. In general, there are two ways to

CONTROL accomplish this. When building a valve or

replacing one in a breakdown scenario, it is
critical to understand the differences in working
principles in order to choose the best valve for
your application.
 PNEUMATICS

Features and Benefits

BISTABLE - Pneumatic actuation type

- Aluminium body material

VALVE - 44232 port thread configuration

- G 1/8 connection port thread size
- 5/2 Bistable function

CONTROL - Maximum flow rate of 740 NL/min

- Maximum operating pressure of 10 bar
- Minimum operating pressure of 1 bar
- Operating temperature range of -10°C to +60°C
- Base mounting style
- Two port positions
SENSORS & SWITCHES
 LIMIT SWITCHES
a device used to detect the position of a
cylinder, specifically signaling when it reaches
the end of its travel or a predetermined point in
its stroke

acts as sensor to monitor the cylinder’s extreme

positions and trigger actions like stopping the
movement when necessary

its function is to ensure accurate and safe

control of the pressing process
 LIMIT SWITCHES
a device that sends an electrical signal to a control system when the cylinder
piston reaches a specific position, in which, this signal triggers various actions,
such as stopping or reversing the direction of the cylinder, depending on the
application requirements; the switch typically consists of an actuator arm that
physically contacts the piston or another part of the cylinder assembly to activate
the sensor
 PROXIMITY SENSORS
an essential component in industrial automation
systems, playing a pivotal role in detecting the
presence or absence of an object without any
physical contact

widely used in manufacturing, robotics, and

other applications where object detection is
necessary

operates on the basis of changes in air pressure

 PROXIMITY SENSORS
the main components of a pneumatic proximity sensor include:
- sensing nozzle: directs a stream of compressed air towards the target object
- diaphragm/piston: converts the changes in air pressure into mechanical motion
- pressure switch: detects the motion of the diaphragm/piston and generates an
electrical signal accordingly

it is also classified into 2 types:

- Positive Pressure Sensors: use compressed air to detect the presence of an
object; the air pressure within the sensing area increases when an object is near,
causing the diaphragm or piston to move and trigger the pressure switch
- Vacuum Pressure Sensors: work on the principle of negative air pressure; create
a vacuum in the sensing area, and when an object approaches, the vacuum is
disturbed, causing a change in pressure that activates the pressure switch
 PROXIMITY SENSORS
Advantages of Pneumatic Proximity Sensors
- low maintenance
- simple installation and operation
- high reliability

Limitations of Pneumatic Proximity Sensors

- slower response times
- energy consumption
- sensitivity to pressure fluctuations
 PRESSURE SENSORS
an electronic device that detects or monitors
either gas or liquid pressure (force) and
converts that information into an electrical
signal that can be used to monitor or regulate
the force being measured

employed for monitoring and control of pressure

in numerous applications, and can also be used
to measure other variables, such as fluid/gas
flow, altitude, and water level
 PRESSURE SENSORS
Types of Pressure Measurement
- Gauge Pressure: relative to the local atmospheric or ambient pressure; the
pressure indicated is either higher or lower than the local atmospheric pressure
- Absolute Pressure: relative to a reference of zero pressure or a vacuum; a
pressure measurement using an absolute pressure sensor will be the same
regardless of where it is measured
- Differential Pressure: the difference in pressure between two points in a system,
which is commonly used to measure the flow of liquid or gas in pipes
- Vacuum Pressure: measures a negative pressure range as compared to
ambient or local atmospheric pressure
- Compound Pressure: measures both positive and negative pressure, or vacuum,
so it is essentially Gauge Pressure and Vacuum Pressure combined
PRESSURE SENSORS
 PRESSURE SENSORS
Types of Pressure Sensors
- Vacuum: used to measure pressure that is below atmospheric levels; use piezo
technology or the measurement of the volume of gas in a particular space
- Sealed: use atmospheric pressure at sea level as the reference pressure
- Vented: measures pressure relative to ambient barometric pressure
- Diaphragm: use thin, flexible, & circular metal plates that deform under pressure
- Strain Gauge: measures resistance caused by change in length due to an
external force and convert it into an electrical signal
- Solid State: employs no moving parts, but instead use a semiconductor
switching element, such as a Field Effect transistor to sense pressure
- Thin Film: utilizes a thin film containing resistive elements that alter resistance
due to length and thickness changes (deformation) induced by pressure
Uses of bi- stable
valve control
•USES OF BI-STABLE VALVE CONTROL

•KEY BENEFITS OF USING BI-STABLE VALVE CONTROL

•SPECIFIC APPLICATION OF BI-STABLE VALVE CONTROL

 IT IS PRIMARILY USED IN APPLICATIONS WHERE A VALVE NEEDS TO MAINTAIN ITS
POSITION (EITHER OPEN OR CLOSED) WITHOUT REQUIRING CONTINUOUS POWER,
MAKING IT IDEAL FOR ENERGY-EFFICIENT SYSTEMS, BATTERY-POWERED DEVICES, AND
SITUATIONS WHERE PRECISE CONTROL OF FLUID OR GAS FLOW IS NECESSARY,
INCLUDING: ROBOTICS, PNEUMATIC SYSTEMS, MEDICAL DEVICES, INDUSTRIAL
AUTOMATION, SAFETY-CRITICAL APPLICATIONS, AND SITUATIONS WHERE POWER
INTERRUPTIONS MIGHT OCCUR; ESSENTIALLY ANYWHERE A "LATCHING" MECHANISM
IS NEEDED TO HOLD A VALVE IN ONE POSITION UNTIL A NEW SIGNAL IS RECEIVED TO
CHANGE IT.
Key benefits of using bi-stable
valve control
•ENERGY EFFICIENCY: ONLY REQUIRES A MOMENTARY PULSE OF POWER
TO SWITCH POSITIONS, NOT CONTINUOUS POWER TO MAINTAIN THE
STATE.

•RELIABLE IN POWER FLUCTUATIONS: MAINTAINS ITS POSITION EVEN

DURING POWER INTERRUPTIONS.

•PRECISE CONTROL: CAN ACCURATELY SWITCH BETWEEN TWO DISTINCT

POSITIONS.

•SUITABLE FOR BATTERY-POWERED SYSTEMS: LOW POWER

CONSUMPTION MAKES IT IDEAL FOR BATTERY-OPERATED DEVICES.
Specific application of bi-stable
valve control
•PNEUMATIC ACTUATORS IN
ROBOTS
CONTROLLING THE
MOVEMENT OF ROBOTIC ARMS
BY DIRECTING AIR PRESSURE TO
DIFFERENT ACTUATORS.
•Medical devices
Precise fluid flow
control in infusion
pumps or other medical
equipment.
 Industrial machinery
Directing fluid or gas flow in automated production lines
 Safety systems
Holding a valve in a safe position until a specific
signal is received
Textile manufacturing
Controlling air pressure for precise
fabric manipulation
 Vending machines
Precise dispensing of liquids or snacks.