ME 3012

INTRODUCTION TO PNEUMATIC CONTROL SYSTEMS

INSTRUCTED BY: Mr. S.H.C.H. Kumara

NAME COURSE INDEX NO GROUP FEILD DATE OF SUB

: Gunasekera N.P.A. : B.Sc. Engineering : 090160U : 04 : Mechanical : 05.04.2012

INTRODUCTON Pneumatics is a branch of technology that deals with the study and application of pressurized gas to effect mechanical motion. In pneumatic systems compressed air is produced in a compressor and stored in a receiver. From here it is routed to valves which control the direction of fluid flow, flow control valves which control the amount of power produced by the cylinders which converts the potential energy of the compressed air into kinetic energy at the output. Pneumatics systems are being widely used in industrial automation mainly due to its simplicity in installation and maintenance, fast operation, environmental friendliness even in case of leakage, low operational and maintenance cost.

EXPERIMENT Introduction to pneumatic control systems OBJECTIVES interpret pneumatic systems and circuit diagrams describe the operation of pneumatic systems pipe-up/construct pneumatic systems have an appreciation of safety requirements when operating pneumatic systems To get an overall idea about compressed air systems

PROCEDURE
A pneumatic control system was designed and simulated using FluidSIM software and made the designed system using actual components. The design considerations of the system were as follow. At the initial position, both cylinders were in the retracted state. Therefore, two limit switches, 1S1 and 2S1 are activated. To start the cycle, both 2S1 and push button valve must be activated. When the cycle starts, piston of C1 advanced slowly and when it came to the position of 1S2, the piston of C2 started advancing. When the piston of C2 reached 2S2, piston C1 retraced quickly back to the initial position of it. When the piston of C1 reaches back to 1S1 position, C2 also retraced back to its initial position. Then the cycle could be repeated with the press of the push button. 2S1 2S2

C2 1S1 1S2

C1

DISCUSSION 1. Components of a pneumatic control system

a) Compressor: Pump that compresses air, raising air pressure to above ambient pressure for use in pneumatic systems. There are several types of compressors used in the industrial.

I.

Reciprocating compressors

Reciprocating air compressors are positive displacement compressors. This means they are taking in successive volumes of air which is confined within a closed space and elevating this air to a higher pressure. The reciprocating air compressor accomplishes this by using a piston within a cylinder as the compressing and displacing element.

II.

Rotary Screw Compressors

Rotary air compressors are positive displacement compressors. The most common rotary air compressor is the single stage helical or spiral lobe oil flooded screw air compressor. These compressors consist of two rotors within a casing where the rotors compress the air internally. There are no valves. These units are basically oil cooled (with air cooled or water cooled oil coolers) where the oil seals the internal clearances. Since the cooling takes place right inside the compressor, the working parts never experience extreme operating temperatures. The rotary compressor, therefore, is a continuous duty, air cooled or water cooled compressor package.

III.

Centrifugal Compressors

The centrifugal air compressor is a dynamic compressor which depends on transfer of energy from a rotating impeller to the air. The rotor accomplishes this by changing the momentum and pressure of the air. This momentum is converted to useful pressure by slowing the air down in a stationary diffuser.

IV.

Rotary sliding vane compressor

A sliding (rotary) vane compressor has a solid rotor mounted inside a water jacketed cylinder, similar to that of a jacketed water section of a reciprocating cylinder. The water jacket around the cylinder is used for cooling. The rotor is filled with blades that are free to move in and out of the longitudinal slots in the rotor. Blade configurations range from 8 to 12 blades, depending upon manufacturer and pressure differentials. The blades are forced out against the cylinder wall by centrifugal force, creating individual cells of gas which are compressed as the rotor turns. As it approaches the discharge port, this area is reduced and the gas discharged.

b) Pneumatic Cylinder or Linear Actuator These devices are used to apply straight line (linear) pushing or pulling forces. Linear actuators are available in thousands of different configurations. These cylinders are fitted with pistons of various diameters and strokes of various lengths. They are most commonly specified as single acting (powered in one direction) or double acting (powered in both directions). Single acting spring return cylinders are more economical with respect to air consumption. c) Solenoid Valve Solenoid valves are electrically operated valves that control the direction and flow of pressurized air to and from pneumatic actuators or circuits. Solenoid valves can be either monostable, (they spring return to a default condition either on or off) or Bi-stable, (having no preferred or default condition thus remaining where it was last positioned either on or off) Pneumatic valves can be operated by hand, (mechanical) electrically (solenoid) or air (piloted) operated. Ports and Positions of a 3-2 Valve The first number 3, refers to the number of ports or holes through which air moves into or out of the valve and the 2 refers to the number of valve positions or conditions.

d) Regulator Regulators control circuit pressure or force.These devices are fitted with mechanical components that react to changes in the downstream air pressure. The regulator attempts to automatically maintain a constant (preset) pressure within a pneumatic circuit as long as the supply (reservoir) pressure is greater than the required circuit pressure. The reading on the regulator-mounted gauge indicates the regulated or circuit pressure.

e) Operation of filters A pneumatic filter is a type of filter specifically designed for use in a compressed air stream. Filters are devices used to remove contaminants from a stream of liquid or gas. Pneumatic filters remove contaminants, especially solid particulates, from streams of fluid in the form of compressed air. They are frequently used in sequence with secondary filters that trap even smaller particles that escape the primary filters.

2. Advantages and limitations

Advantages Reliable, economical actuators. Pneumatic actuators, the air-powered motors which control valves and dampers, remain the most reliable, durable, and economical actuators available. They require essentially no maintenance except for inspection and adjustment of the echanical linkages. It is easy to select actuators which fail in the desired position upon loss of electric power (and thus pneumatic air pressure). Pneumatic actuators, of all sizes, cost much less than corresponding electric/electronic actuators. Flexible, modular control components. The complete pneumatic control system are distributed throughout the building using numerous pneumatic building blocks such as thermostats, receiver controllers, and pneumatic relays. Virtually any control strategy can be implemented by a custom-designed pneumatic control system. Pneumatics can provide excellent control performance and can maintain set points accurately. Compressed gas can be stored, allowing the use of machines when electrical power is lost. Safety is assured, o Very low chance of fire (compared to hydraulic oil). o Machines can be designed to be overload safe.

Limitations Good maintenance is required. Pneumatics require two important types of maintenance. The first is to ensure that the pneumatic air supply is clean, reliable, and dry at all times. The second is to carry out a program of routine and preventative maintenance under which all control components are inspected and, if necessary, adjusted every couple of years or so. Pneumatic controls are not well-suited for remote monitoring of space conditions and mechanical equipment status.

3. Practical applications of pneumatic systems

Air brakes on buses and trucks Air brakes, on trains Air compressors Air engines for pneumatically powered vehicles Cable jetting, a way to install cables in ducts Compressed-air engine and compressed-air vehicles Gas-operated reloading Holman Projector, a pneumatic anti-aircraft weapon Inflatable structures Lego pneumatics can be used to build pneumatic models Exercise machines Pipe organs