PNEUMATICS

Meralco Foundation

INTRODUCTION
Pneumatics is the study of air movement and air phenomena. It is derived from the Greek term pneuma which means breath or wind. Pneumatic equipment is interpreted as a systems machine and devices operated by or relying upon an air pressure or vacuum. Pneumatics started when the need for automation and rationalization of operational sequences continued to increase. Pneumatics is usually used in areas where fire or explosion hazards exist.
Meralco Foundation

Intro.
Pneumatics System Force Up to 3 tons Hydraulic System Higher forces

Speed
Prime mover Medium

Erratic (fast)
Compressor (receiver Air (exhausted to atmosphere)

Smooth
Pump (tank) Oil ( return to tank)

Hydraulics
defined as branch of science which treats of water or other fluid in motion. Comes from the Greek word hydor meaning water and aulos meaning tube or pipe.

In hydraulic system water, oil or other liquid can be used. A fluid system that uses compressed air is called pneumatic system and a fluid system that uses oil is called a hydraulic system. Fluids are substances capable of flowing, having particles which easily move and change their relative position without a separation of mass.
Meralco Foundation

A Typical Pneumatic System

AIR COMPRESSOR

DRIVING MEANS

MAIN FILTER

TAKE OFF

PIPING SYSTEM (SLOPING)

CYLINDER PRESSURE CONTROL

AUTO/MANUAL DRAIN FUNCTIONAL CONTROL

AFTER COOLER SHUT-OFF VALVE

DIRECTIONAL CONTROL

SUPPLY VALVE

AIR RECEIVER
AIR SERVICE UNIT AIR DRYER AIR FILTER PRESSURE REGULATOR AIR LUBRICATOR

Meralco Foundation

PNEUMATIC WORKING ELEMENTS

Meralco Foundation

a. CYLINDERS
PURPOSE:
The cylinder is a common device for producing linear movement with force.

APPLICATION:
Clamping and Releasing Lifting and Lowering Pushing and Pulling Opening and Shutting Feeding, etc.
Meralco Foundation

Construction and working principle

The Single-Acting Pneumatic Cylinder
Can produce work only in one direction because the compressed air is applied to one side only.
If cylinder positive chamber (+) is supplied with compressed air a pressure acts on the piston surface. If the force generated by the pressure [ F = Pressure (P) x Piston Area (A)] is greater than the counter force of the spring, the piston moves with the piston rod to the right. This movement is termed forward of positive stroke. If the compressed air supply is interrupted, the spring force is sufficient to move the piston to the left (-) and exhaust the positive chamber. This movement is called return or negative stroke.

Meralco Foundation

Construction and working principle

The double-acting Pneumatic Cylinder
The force exerted by the compressed air moves the piston in two directions where a definite force is applied on both advance and return movement.
If compressed air is supplied to the positive cylinder chamber and the negative chamber is exhausted, the positive stroke is carried out. Similarly, the return stroke is effected when the negative chamber is supplied with air and the positive chamber is exhausted.

Meralco Foundation

Types of cylinders

Single-acting cylinders
Compressed air is applied on one side only.

Diaphragm cylinders
is also called pancake cylinder or clamping cylinder. With built in diaphragm, which can be made of rubber, plastic or even metal, replaces the function of the piston

Rolling Diaphragm cylinders

Construction is similar with the diaphragm cylinder. When compressed air is admitted, the diaphragm unrolls along the inner wall of the cylinder and moves the piston rod outwards.

Double-acting cylinders
The force exerted by the compressed air moves the piston in two directions.

Double sided piston rod cylinders

Has a piston rod protruding from both sides.

Impact cylinders
A cylinder that produces high kinetic energy. Stroke velocity is 7.5 10 m/s
Meralco Foundation

Types of cylinders

Cable cylinders
A double acting cylinder, where a cable is attached to each side of the piston and guided over rollers. Used in door operation, small-sized unit producing large stroke length.

Tandem cylinders

The design involves two double-acting cylinders which have been joined to form a single unit. By this arrangement and simultaneous loading of both pistons, the force on the piston rod is almost doubled. This design is needed for such applications where a large force is required but the cylinder diameter is restricted.

Multi-position cylinders
Consist of two or several double acting cylinders

Rotary cylinder

Meralco Foundation

PNEUMATIC INPUT AND CONTROL ELEMENT Directional Control Valves Non-return Valves Pressure Control Valve Flow Control Valves Shut-off Valves Time Delay Valves Pneumatic amplifiers Pneumatic Counters
Meralco Foundation

RULES ON REPRESENTATIONOF DIRECTIONAL VALVES

1.
2.

3.
4. 5. 6.

Symbols are used for representing valves in circuit diagrams. These symbols specify only the function of the valve, but do not indicate the design principle which it is constructed. Valve switching position are represented as square. The number of adjacent squares shows how many switching position the valve has. The function and working principle is drawn inside the boxes (squares). Lines indicate flow paths. Arrow shows the direction of flow. Shut-off positions are identified in the boxes by lines drawn at right angles. Flow path junctions within a valve are represented by a dot. The connections (inlet and outlet ports) are shown by lines drawn on the outside of the box representing the normal or initial positions.

Meralco Foundation

RULES ON REPRESENTATIONOF DIRECTIONAL VALVES

7. The other position is obtained by shifting the squares until the flow paths correspond to the connections. The switching positions may be identified by lower case letters o,a,b,c.. Valve with 3 switching positions has the mid-position or neutral position identified by lower case letter o. Exhaust flow path without pipe connection (free exhaust) is represented by triangle directly on the symbol. Exhaust flow path with pipe connection (contained exhaust) is represented by a triangle not directly on the symbol. To ensure that the valve is properly installed, the connections are labelled with capital letters or numbers. Working lines A,B,C. . . . . . .2,4,6 Power connections P . . . . . . . . . .1 Exhaust R,S,T. . . . . . . 3,5,7 Control Lines Z,Y,X. . . . . . . 12,14, 16
a b

8. 9. 10. 11.

Meralco Foundation

RULES ON REPRESENTATIONOF DIRECTIONAL VALVES

12. The designation of a valve is based on the number of controlled connections and number of switching positions. The first number in the designation specifies the number of paths, or the controlled connections. The second number specifies the switching positions of the valve. Number of controlled connections or Example:
Number of paths or number of ports = 3/2 way valve Number of switching positions
Meralco Foundation

Design Characteristics of Directional Valves

Designs are categorized as follows:
POPPET VALVES
Ball seat valve Disc seat valve

SLIDE VALVES
Longitudinal slide valve Longitudinal flat slide valve Plate slide valve (butterfly valve)

Meralco Foundation

SOLENOID VALVE
These valves are used where the switching impulse emanates from an electrical timing device, electrical limit switches, pressure probes or electronic controllers. Is normally selected for controls involving extremely long distances and for short switching time.
Meralco Foundation

NON RETURN VALVE

are devices which preferentially stop the flow in one direction and permit flow in the opposite direction.

Meralco Foundation

CHECK VALVE
Can stop the flow completely in one direction and the air flows in the opposite direction with as low a pressure loss as possible. Blocking of one direction can be effected by cones, balls, plates or diaphragms.

Meralco Foundation

SHUTTLE VALVE
Is also called double control valve or double check valve. It has two inlets X and Y and one outlet A. It is also called OR valve.

Meralco Foundation

THROTTLE RELIEF VALVE

Is also known as SPEED REGULATING VALVE. A check valve blocks the flow of air in one direction and air can flow only in a regulated cross-section. In the opposite, the air can flow freely through the open check valve. If possible, throttle relief valve should be mounted directly on the cylinder.

Meralco Foundation

QUICK EXHAUST VALVE

Is used to increase the piston speed in cylinder when returning to its initial position. is directly mounted on the cylinder or as near to it as possible.

Meralco Foundation

TWO PRESSURE VALVE

It has two inlets, X and Y and one outlet A. Compressed air will flow through only if signal are applied to both inlets. May be used as interlocking control, safety control check function or logic operations.

Position when signal is applied on both inlets

Position when signal is applied on X inlet

Position when signal is applied on Y inlet

Meralco Foundation

TIME DELAY VALVE

Also known as Pneumatic actuation with delayed switch-over. Consist of a pneumatically controlled 3/2 way valve, a throttle relief valve and a small air reservoir.

Meralco Foundation

REFLEX SENSOR

A Meralco Foundation

APPLICATIONS

Meralco Foundation

APPLICATIONS: Allocating device (DIRECT CONTROL OF CYLINDER)

The allocating device supplies valve blanks to a machining station. By operating a push button, the piston rod of a single acting cylinder is made to advance. After releasing the actuating button the piston rod returns.

Meralco Foundation

APPLICATIONS: DISTRIBUTION CRATES

(Direct Control of a Double-acting Cylinder)

The roller track is to swivel at will by means of a manual control. After actuating the push button the piston rod of the cylinder is to extend. On releasing the manual control, the initial position is to be resumed.

Meralco Foundation

INDIRECT CONTROL OF CYLINDERS

PROBLEM: Sorting device for metal stampings Through operation of the push button on the indirectly actuated valve, metal stampings lying in random positions are sorted out and transferred to a second belt conveyor belt. When the push button is released, the piston rod of a single-acting cylinder travels to the retracted end position.

Meralco Foundation

SOLUTION:

Meralco Foundation

INDIRECT CONTROL OF A DOUBLE ACTING CYLINDER

PROBLEM: OPENING AND CLOSINGDEVICE By using a large volume double-acing cylinder, the valve in a pipe line is to be opened and closed. The valve is opened by pressing the push button switch. When the push button is released the valve is closed.

Meralco Foundation

SOLUTION:

Meralco Foundation

CONTROL WITH TWO PRESSURE VALVE

PROBLEM: CUTTING DEVICE Using a cutting device, sheets of metal are to be cut to size. By pressing two push button switches, the cutting blade is advanced by a double acting cylinder and the sheets of metal is cut. When the push button switch is released, the blade returned to its initial position.

Meralco Foundation

SOLUTION:

Meralco Foundation