Pneumatics

11/9/2010
PNEUMATICS
UNIT 5
Notes.NieRoyalMech.com
SYLLABUS
Unit-5: Directional Control Val ves: Symbolic representation as per IS 1219 and IS 5599. Design and constructional aspects, poppet valves, slide valves spool valve. Simple Pneumatic control : direct and indirect actuation of pneumatic cylinder, Use of memory valve. Flow control valves and Speed control of cylinders- supply air throttling and Exhaust air throttling use of Quick exhaust valve.
Signal processing elements: Use of Logic gates OR and AND gates in pneumatic applications. Practical examples involving the use of logic gates. Pressure dependent controls-typesconstruction-practical applications. Time dependent controlsprinciple, construction, practical applications . 10 Hrs
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Directional Control Valves
Directional Control valves are mainly used to change the direction of
f low path of working medium or signal medium.

Directional control valves are designated as per the f ollowing
f unctions: Number of ports on the valves Number of switching positions Method of actuation Method of reset Design and constructional f eatures
Construction of 3/2 directional valve

Distributing spool
Outlet port
Spring
Housing
Exhaust port
Pressure inlet port
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Port Marking of Direction Control Valve
As per IS-1219
Supply Port P Exhaust Ports R & S Out put Ports A & B Pilot Port [Set ] Z Pilot Port [Reset]Y
As per IS 5599
Supply Port 1 Exhaust Port 3 & 5 Out put Ports2 & 4 Pilot Port [Set] 14 Pilot Port [Reset]12
Pneumatically operated directional control valve
The 5/2 directional control valves, operated by pneumatic impulse is applied in various practical solutions such as: pushing of loads; applying tools for performing operations, opening/closing doors and windows, stretch/bend of robot/manipulator arms.
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Pneumatically operated directional control valve

Control input
Valve spool
Outlet ports
Control input
Housing
Exhaust port
Pressure inlet port
Exhaust port
Symbolic Representation
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Methods of Actuation
Quick Exhaust Valve
In many applications especially with single acting cylinders, it is a common practice to increase the piston speed during retraction of the cylinder to save the cycle time This is carried out by incorporating a Quick exhaust valve. The Quick exhaust valve has essentially three ports
Supply port 1, is connected to the out put of the final control element (Directional control valve). The Output port, 2 of this valve is directly fitted on to the working port of cylinder. The exhaust port, 3 is left open to the atmosphere
2 1 3
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Quick Exhaust Valve
Use of Quick Exhaust Valve
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Controlling of Pneumatic Cylinders
Pneumatic cylinders can be controlled by the following methods:

1. Direct control of Single or Double acting cylinder 2. Indirect Control of Cylinder with Single Piloted Final Control Valve 3. Indirect Control of Cylinder with Double Piloted Final Control Valve
In the indirect control actuation, a pilot signal from a 3/2 N.C. valve is used to activate pilot ports of final control valve.
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Direct Control of Single Acting Cylinder
Pneumatic cylinders can be directly actuated by actuation of final control valve , manually or electrically
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Indirect Control of Single Acting Cylinder
Large cylinders as well as cylinders operating at high speed are generally actuated indirectly as the final control valve is required to handle large quantity of air.
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Use of Double Piloted Valve

Double piloted valve is also called as the Memory valve
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Use of Limit Switches

S1 F=0 S2
4 14
2 12
5 2 S1 1 3
3 2 S2 1 3
Use of Mechanically operated Roller lever Limit Switches
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Speed Control Of Cylinders
It is always necessary to reduce the speed of cylinder f rom
maximum speed based on selected size of f inal control valve to the nominal speed depending on the application
Speed control of Pneumatic Cylinders can be conveniently
achieved by regulating the f low rate supply or exhaust air.

The volume f low rate of air can be controlled by using flow
control valves which can be either Two way f low control valve or One way f low control valve
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One-way flow control valve
The pneumatic one-way f low control valve is also ref erred to as a
pneumatic throttle valve. Throttle valves are used in many pneumatic systems to control air f low.
There are two basic types of throttles - adjustable and non-
adjustable, the adjustable version is the most commonly used. When using adjustable flow-control valves the user can adjust the eff ective throttling area to best suit the air f low needs of the individual application.
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Construction of flow control valve
Housing
Regulating screw
Spring
Port 1
Check valve
Port 2
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Use of Flow Control Valve for Speed Control of Cylinder

Parts List
Sl. No.
1
Component
Double acting cylinder 5/2 DCV Solenoid operated, spring return Throttle check valve
Symbol
Quantity
1
FRL Unit
20
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Use of Flow Control Valve for Speed Control of Cylinder

Supply air throttling / exhaust air throttling
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Supply air throttling / exhaust air throttling

Supply Air Throttling
Supply air entering the cylinder through either of the working ports, undergoes throttling as the non
return valve is closed in the direction of flow.

During exhaust , the compressed air leaving the cylinder is by passed through the non return valve
and escapes freely as it does not under go throttling

Supply air throttling is used for single acting cylinder and small volume cylinder
Exhaust Air Throttling
Supply air flows freely to the cylinder through the bypass passage of the non return valve. The
supply air does not under go any throttling Exhaust air leaving the cylinder has to under go throttling as the non return valve is closed in the return direction The piston is loaded between two cushions of air Exhaust throttling should always be used for double acting cylinder Not suitable for small volume cylinders and cylinders with short strokes as effective pressure cannot build up sufficiently.
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Signal processing elements

To meet the requirement of various conditions in pneumatic applications, signal processing devices are often used. The following gates or valves are used, depending on the required conditions.
OR Gate Shuttle Valve Used to select one of the two input signals AND Gate- Two Pressure Valve- To combine two input signals i.e satisfy two conditions at the same time to
NOT Gate- 3/2 way, normally open, pilot operated Directional Control Valve- used to negate the function
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Shuttle Valve as OR gate
An Input Signal [1] can be applied on either side of the valve to obtain an out put signal at port 2. A small aluminum or plastic ball or spool is used as the shuttle which blocks the port opposite to the input signal.
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Selection of Parts
Sl. No.
1 2 3
Component
Double acting cylinder 5/2 Way Directional Control Valve (Single Piloted) 3/2 way Push button valve (NC)
Numbers
1 1 2
4
5
Shuttle valve
Air Service unit (Filter Regulator assembly)
1
1
25
26
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Twin Pressure Valve as AND Gate
Input signal applied on any one side of the valve will block the signal passage on the same side of the port.
If a second signal is applied on the opposite side at the same time, it will be communicated to the out put port.
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Selection of Parts
Sl. No.
1
Component
Double acting cylinder
Numbers
1
2 3
4 5
5/2 Way Directional Control Valve (Single Piloted) 3/2 way Push button valve (NC)
Two pressure valve Air Service unit (Filter Regulator assembly)
1 2
1 1
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Circuit Diagram
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Not Gate
2 10
Not Gate is generally used to invert the signal status i. e to negate the signal. For example a normally closed timer or counter can be converted to normally open and vice versa
It is essentially a normally open 3/2 way, pilot operated directional control valve. Input signal is applied at pilot port 10 and out put is taken from port 2.
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Logical Control With Shuttle And Twin-pressure Valves
Task: The Piston of double acting cylinder of a supply station supplies work pieces under the following logical conditions:
The start button (S0) or an auxiliary button (S1) is actuated and parts are available in the work piece magazine (B2)
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An optical display shows whether there are still enough parts available in the magazine
The cylinder should only retract into its back end position if it has actuation reached the front end position and an acknowledgement button (S4) is actuated.
A 5/2 impulse valve is used as an actuator. Additionally: for scanning work pieces in the magazine (B2) it is not possible lto use a mechanically operated signaler. The scanning should therefore occur in a non-contact manner through a reflex sensor. The working speed of the cylinder should be infinitely adjustable in both directions
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Pneumatic circuit
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Pneumatic Timers
Figure : Pneumatic Timers- Normally closed and Normally Open
A Pneumatic Timer is a combination valve which consists of three parts 1. 3/2 way pilot operated directional control valve [NC or NO], 2. A one way flow control valve and 3. An accumulator
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Pneumatic Timers
e represents the signal status of input signal a represents the signal status of output signal Output signal appears after lapse of time t after input signal is Introduced in ON delay timer while in OFF delay timer the out put signal disappears after a time lag after input signal is introduced 0 state corresponds to no signal while1 state corresponds to presence of signal
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Time Delay Valve [N.C]
Signal input is supplied at port 12 and delayed signal out put is taken at 2. A signal source is connected at port 1
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Pneumatic Timers
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Pneumatics

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11/9/2010

Directional Control Valves

Directional Control valves are mainly used to change the direction of

f low path of working medium or signal medium.

Construction of 3/2 directional valve

Pressure inlet port

Port Marking of Direction Control Valve

Pneumatically operated directional control valve

Pneumatically operated directional control valve

Pressure inlet port

Quick Exhaust Valve

Quick Exhaust Valve

Use of Quick Exhaust Valve

Controlling of Pneumatic Cylinders

Pneumatic cylinders can be controlled by the following methods:

Direct Control of Single Acting Cylinder

Indirect Control of Single Acting Cylinder

Use of Double Piloted Valve

Use of Limit Switches

Use of Mechanically operated Roller lever Limit Switches

Speed Control Of Cylinders

It is always necessary to reduce the speed of cylinder f rom

achieved by regulating the f low rate supply or exhaust air.

One-way flow control valve

The pneumatic one-way f low control valve is also ref erred to as a

Construction of flow control valve

Use of Flow Control Valve for Speed Control of Cylinder

Use of Flow Control Valve for Speed Control of Cylinder

Supply air throttling / exhaust air throttling

return valve is closed in the direction of flow.

and escapes freely as it does not under go throttling

Exhaust Air Throttling

Signal processing elements

Signal processing elements

Signal processing elements

Signal processing elements

Signal processing elements

Signal processing elements

Signal processing elements

Signal processing elements

Logical Control With Shuttle And Twin-pressure Valves

Logical Control With Shuttle And Twin-pressure Valves

Logical Control With Shuttle And Twin-pressure Valves

Figure : Pneumatic Timers- Normally closed and Normally Open

Time Delay Valve [N.C]

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