Академический Документы
Профессиональный Документы
Культура Документы
Technical Reference
Version 1.0
ELECTRO PNEUMATICS
VMPT-302 LC
CHAPTER - 1
INTRODUCTION OF PNEUMATICS
SYSTEM
[1]
ELECTRO PNEUMATICS
1.1
VMPT-302 LC
APPLICATIONS OF PNEUMATICS
Pneumatics deals the use of compressed air, Most commonly, compressed air is used to
do mechanical work-that is to produce motion and to generate forces. Pneumatic drives have the
task of converting the energy stored in compressed air into motion.
Cylinders are most commonly used for pneumatic drives. They are characterized by robust
construction, a large range of types, simple installation and favorable price/performance. As a
result of these benefits, pneumatics is used in a wide range of applications.
1.2
A signal is the representation of information the representation is by means of the value or value
pattern of the physical variable.
[2]
ELECTRO PNEUMATICS
VMPT-302 LC
Signal/physical variable
Pressure
7
bar
5
4
3
2
1
Time
0
Information
a) Analog
Pointer position
7
6
5
4
7
8
2
1
Time
b) Digital
Display
7
6
5
Pressure
bar
4
3
2
1
0
Time
c) Binary
Pressure
Supply
Pressure
Yes 1
No 0
Time
[3]
ELECTRO PNEUMATICS
VMPT-302 LC
Analog signal
An analog signal is a signal in which information is assigned point by point to a continuous value
range of the signal parameter (DIN 19226. Part 5).
Application example
In the case of a pressure gauge, each pressure value (information parameter) is assigned a
particular display value ( = information). If the signal rises or falls, the information changes
continuously.
Digital signal
A digital signal is a signal with a finite number of value ranges of the information parameter. Each
value range is assigned a specific item of information (DIN 19226).
Application example
A pressure measuring system with a digital display shows the pressure in increments of 1 bar.
There are 8 possible display values ( 0 to 7 bar) for a pressure range of 7 bar. That is, there eight
possible value ranges for the information parameter. If the signal rises or falls, the information
changes in increments.
Binary Signal
A binary signal is a digital signal with only two value ranges for the information parameter. If the
signal rises or falls, the information changes in increments.
Application example
A control lamp indicates whether a pneumatic system is being correctly supplied with compressed
air. If the supply pressure ( = signal is below 5 bar, the control lamp is off (0 status). If the
pressure is above 5 bar, the control lamp is on ( 1status).
1.3
A controller can be divided into the functions signal input, signal processing signal output and
command execution. The mutual influence of these functions is shown by the signal flow diagram.
*
Signals from the signal input are logically associated (signal processing). Signals
for signal input and signal process are low power signals. Both functions are part
of the signal control section.
*
At the signal output stage, signals are amplified from low power to high power.
Signal output forms the link between the signal control section and the power
section.
[4]
ELECTRO PNEUMATICS
Command execution take place at a high power level-that is, in order to reach a
high speed (such as for fast rejection of a workpiece form a machine) or to exert
a high force (such as for a press). Command execution belongs to the power
section of a control system.
Command execution
Power
section
VMPT-302 LC
Signal Processing
Signal control
section
Signal output
Signal input
Both pneumatic and electro pneumatic controllers have a pneumatic power section (see fig 1.4).
The signal control section varies according to type.
*
In a pneumatic control pneumatic components are used, that is, various types of
valves, sequences, air barriers, etc.
The directional control valves form the interface between the signal control section and the
pneumatic power section in both types of controller.
[5]
COMMAND EXECUTION
VMPT-302 LC
Power Components
Cylinder
Swivel cylinder
Pneumatic motors
Optical displays
Pneumatic power
section
ELECTRO PNEUMATICS
Electropneumatically
operated directional
control valves
SIGNAL PROCESSING
Relays
Contactors
Programmable logic
controllers (PLCs)
SIGNAL INPUT
Input Elements
Pushbuttons
Control switches
Limit switches
Reed switches
Ind.proximity sensors
Cap.proximity switches
Light barriers
Pressure-actuated
Switches
SIGNAL FLOW
Electropneumatic components
Processing Elements
[6]
ELECTRO PNEUMATICS
VMPT-302 LC
1.5
The electrical signal control section switches the electrically actuated directional control
valves.
The directional control valves cause the piston rods to extend and retract.
The position of the piston rods is reported to the electrical signal control section by
proximity switches.
[7]
ELECTRO PNEUMATICS
1.6
VMPT-302 LC
Electro pneumatic controllers have the following advantages over pneumatic control systems:
*
Electro pneumatic controllers have asserted themselves in modern industrial practice and the
application of purely pneumatic control systems is a limited to a few special applications
[8]
ELECTRO PNEUMATICS
VMPT-302 LC
CHAPTER - 2
FUNDAMENTALS OF ELECTRICAL
TECHNOLOGY
[9]
ELECTRO PNEUMATICS
2.1
VMPT-302 LC
A simple electrical circuit consists of a voltage source, a load, and connection lines.
Physically, charge carriers electrons move through the electrical circuit via the electrical
conductors from the negative pole of the voltage source to the positive pole. This motion of
charge carriers is called electrical current. Current can only flow if the circuit is closed.
There are two types of current - direct current and alternating current:
*
If the electromotive force in an electrical circuit is always in the same direction, the
current also always flows in the same direction. This is called direct current (DC) or a DC
circuit.
In the case of alternating current or an AC circuit, the voltage and current change
direction and strength in a certain cycle.
Alternating current
Time t
Current 1
Current 1
Direct current
Time t
[ 10 ]
ELECTRO PNEUMATICS
VMPT-302 LC
3
S
4
V=12V
+
H
Ohms Law
Electrical conductors
Electrical current is the flow of charge carriers in one direction. A current only flow in a material
if a sufficient number of free electrons are available. Materials that meet this criterion are called
electrical conductors. The metals copper, aluminum and sliver are particularly good conductors.
Copper is normally used for conductors in control technology.
Electrical resistance
Every material offers resistance to electrical current. This results when the free-moving electrons
collide with the atoms of the conductor material, inhibiting their motion. Resistance is low in
electrical conductors. Materials with particularly high resistance are called insulators. Rubber
and plastic-based materials are used for insulation of electrical wires and cables.
[ 11 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Source emf
The negative pole of a voltage source has a surplus of electrons. The positive pole has a deficit.
This difference results in source emf (electromotive force).
Ohms law
Ohms law expresses the relationship between voltage, current and resistance. It states that in a
circuit of given resistance, the current is proportional to the voltage, that is
*
*
R.I
V
R
I
=
=
=
Voltage;
Resistance;
Current;
Electrical Power
In mechanics, power can be defined by means of work. The faster work is done, the greater the
power needed. So power is work divided by time.
In the case of a load in an electrical circuit, electrical energy is converted into kinetic energy (for
example electrical motor), light (electrical lamp), or heat energy (such as electrical heater,
electrical lamp). The faster the energy is converted, the higher the electrical power so here, to
power means converted energy divided by time. Power increases with current and voltage.
The electrical power of a load is also called its electrical power input.
P
P
V
I
=
=
=
=
V.I
Power;
Voltage;
Current;
Unit
Unit
Unit
:
:
:
Watt (W)
Volt (V)
Ampere (A)
Application example
Power of a coil
The solenoid coil of a pneumatic 5/2 - way valve is supplied with 24V DC. The resistance of the
coil is 60ohm. What is the power?
The current is calculated by means of ohms law:
[ 12 ]
ELECTRO PNEUMATICS
VMPT-302 LC
V
24V
0.4 A
R
60
Function of a solenoid
A magnetic field is induced when a current is passed through an electrical conductor. The strength
of the magnetic field is proportional to the current. Magnetic fields attract iron, nickel and cobalt.
The attraction increases with the strength of the magnetic field.
Air-core coil
An iron core is placed in the centre. When current flows, the iron is also
magnetized. This allows a significantly higher magnetic field to be induced with
the same current (compared to an air-core coil)
[ 13 ]
ELECTRO PNEUMATICS
VMPT-302 LC
These two measures ensure that an solenoid exerts a strong force on ferrous (=containing iron)
materials.
Applications of solenoids
In electro pneumatic controls, solenoids are primarily used to control the switching of valves,
relays or contractor. This can be demonstrated using the example of the spring-return directional
control valve:
*
If current flows through the solenoid coil, the piston of the valve is actuated.
If the current is interrupted, a spring pushes the piston back into its initial position.
Reactance in AC circuits
If a AC voltage is applied to a coil, an alternating current flows. This means that the current and
magnetic field are constantly changing. The change in the magnetic field induces a current in the
coil. The induced current opposes the current that induced the magnetic field. For this reason,
a coil offers resistance to an alternating current. This is called reactance.
The reactance increases with the frequency of the voltage and the inductance of the coil.
Inductance is measured in Henry (H)
1H 1
VS
1S
A
Reactance in DC circuits
In the case of DC circuits, the current, voltage and magnetic field only change when the current
is switched on. For this reason reactance only applies when the circuit is closed (switching on the
current)
In addition to reactance, the coil has ohmic resistance. This resistance applies both to AC circuits
and DC circuits.
2.4
Function of a capacitor
A capacitor consists of two metal plates with an insulating layer (dielectric) between them. If the
capacitor is connected to a DC voltage source closing the switch S1 in by this. If the circuit is
then interrupted, the charge remains stored in the capacitor. The larger the capacitance of a
capacitor, the greater the electrical charge it can store for a given voltage.
[ 14 ]
ELECTRO PNEUMATICS
VMPT-302 LC
1F 1
AS
V
If the charged capacitor is now connected to a load (closing switch S2 in Fig. 2.6), the capacitor
discharges. Current flows through the load until the capacitor is fully.
Air-core coil
mA
mA
S1
S2
V
+ + + + + +
-
- - - - -
Function of a diode
Diodes are electrical components that only allows current to flow in one direction
*
In the flow direction, the resistance is so low that the current can flow unhindered.
If a diode is inserted into a AC circuit, the current can only flow in one direction. The current is
rectified.
The effect of a diode on an electrical circuit is comparable to the effect of a non-return valve on
a pneumatic circuit.
[ 15 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Voltage V
Time t
Current I
Time t
Measurement
Measurement means comparing an unknown variable (such as the length of a pneumatic cylinder)
with a known variable (such as the scale of a measuring tape). A measuring device (such as a
ruler) allows such measurements to be made. The (such as 30.4 cm)
[ 16 ]
ELECTRO PNEUMATICS
VMPT-302 LC
The multimeter can only measure correctly if the correct mode is set. Devices for measuring
voltage are also called voltmeters. Devices for measuring current are also called ammeters.
V
DC
+
10
20
30
40
DC
DATA/HOLD
AUTO
AC
PEAK HOLD
RANGE
TTL
A
mA
mV
OFF
F
nF
+
Cx
10A
!
A
A
mA
TTL
V
COM
!
400 mA
MAX
500V MAX
1000V
750V
[ 17 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Danger
*
Before carrying out a measurement, ensure that voltage of the controller on which
you are working does not exceed 24V!
2.7
For pointer instruments, always view from vertically above display in order to
avoid parallax error.
Voltage Measurement
For voltage measurement, the measuring device (voltmeter) is connected in parallel to the load.
The voltage drop across the load corresponds to the voltage drop across the measuring device.
A voltmeter has an internal resistance. In order to avoid an inaccurate measurement, the current
flowing thought the voltmeter must be as small as possible, so the internal resistance of the
voltmeter must be as high as possible.
[ 18 ]
ELECTRO PNEUMATICS
VMPT-302 LC
V Voltmeter
Current Measurement
For current measurement, the measuring device (ammeter) is connected in series to the load. The
entire current flows through the device
Each ammeter has an internal resistance. In order to minimize the measuring error, the resistance
of the ammeter must be as small as possible.
Ammeter
[ 19 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Resistance Measurement
The resistance of a load in a DC circuit can either be measured directly or indirectly.
*
Indirect measurement measures the current through the load and the voltage across the
load (Fig.2.9a). The two measurements can either be carried out simultaneously or one
after the other. The resistance is then measured using ohms law.
For direct measurement the load is separated from the rest of the circuit (Fig.2.9b). The
measuring device (ohmmeter) is set to resistance measurement mode and connected to the
terminals of the load. The value of the resistance is displayed.
If the load defective (for example, the magnetic coil of a valve is burned out), the measurement
of resistance either results in a value of zero (short-circuit) or an infinitely high value (open
circuit).
Warning
The direct method must be used for measuring the resistance of a load in AC circuits.
Current I
A
Voltage V
R=V
I
[ 20 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Sources of error
Measuring device cannot measure voltage, current and resistance to any desired degree of
accuracy. The measuring device itself influences the circuit it is measuring, and no measuring
device can display a value precisely. The permissible display error of a measuring device is given
as a percentage of the upper limit of the effective range. For example, for a measuring device
with an accuracy of 05, the display error must not exceed 0.5% of the upper limit of the effective
range.
Application example
Display Error
A class 1.5 measuring device is used to the measure the voltage of a 9V battery. The range is set
once to 10V and once to 100V. How large is the maximum permissible display error for the two
effective ranges?
Range
10V
10V .
100V
Percentage error
15
.
015
. V
100
015
.
.100 166%
.
9V
15
.
15
.V
100
15
.
. 100 16.6%
9V
100V .
[ 21 ]
ELECTRO PNEUMATICS
VMPT-302 LC
CHAPTER - 3
COMPONENTS AND ASSEMBLIES IN THE
ELECTRICAL SIGNAL CONTROL SECTION
[ 22 ]
ELECTRO PNEUMATICS
3.1
VMPT-302 LC
The signal control section of an electro pneumatic controller is supplied with power via the
electrical mains. The controller has a power supply unit for this purpose (see Fig. 3.1). The
individual assemblies of the power supply unit have the following tasks:
*
The transformer reduces the operating voltage. The mains voltage (i.e. 230V) is applied
to the input of the transformer. A lower voltage (i.e.24V) is available at the input.
The rectifier converts the AC voltage into DC voltage. The capacitor at the rectifier
output smooths the voltage.
The voltage regulator at the output of the power supply unit is required to ensure that the
electrical voltage remains constant regardless of the current flowing.
Fig. 3.1 : Component parts of a power supply unit for an electro pneumatic controller.
Rectifier
Transformer
Stabilization
Powersupply unit
Safety Precaution
*
Because of the high input voltage, power supply units are part of the power
installation (DIN /VDE 100).
[ 23 ]
ELECTRO PNEUMATICS
3.2
VMPT-302 LC
Switches are installed in circuits to apply a current to a load or to interrupt the circuit. These
switches are divided into pushbuttons and control switches.
*
Control switches are mechanically detented in the selected position. The switch
position remains unchanged until a new switch position is selected. Example;
Light switches in the home.
Push button switches only maintain the selected position as long as the switch is
actuated (pressed). Example : Bell push.
[ 24 ]
ELECTRO PNEUMATICS
VMPT-302 LC
2.Switch element
3.Contact
In this case, the circuit is closed when the switch is in its initial position. The circuit is interrupted
by pressing the pushbutton.
1.
2.
Contact
3. Switch element
[ 25 ]
ELECTRO PNEUMATICS
3.4
VMPT-302 LC
Changeover contact
The changeover contact combines the functions of the normally open and normally closed
contacts in one device. Changeover contacts are used to close one circuit and open another in
one switching operation. The circuits are momentarily interrupted during changeover.
1.
2.
3.
4.
Switching element
Contact (Normally open
contact)
Sensors have the task of measuring information and passing this on to the signal processing part
in a form that can easily be processed. In electropnematic controllers, sensors are primarily used
for the following purposes:
*
*
*
No to detect the advanced and retracted end position of the piston rod in cylinder
drives
To detect the presence and position of work pieces
To measure and monitor pressure
Limit switches
A limit switch is actuated when a machine part or workpiece is in certain position. Normally,
actuation is effected by a cam. Limit switches are normally changeover contacts. They can then
[ 26 ]
ELECTRO PNEUMATICS
VMPT-302 LC
1.
Guide pin
4.
2.
3.
Compressing spring
7.
8.
9.
Contact (Normally
open contact)
Contact blade
Contact (normally
closed contact)
Proximity switches
[ 27 ]
ELECTRO PNEUMATICS
*
*
*
*
VMPT-302 LC
Reed switch
Inductive proximity switch
Capacitive proximity switch.
Optical proximity switch.
Reed switch
Reed switches are magnetically actuated proximity switches. They consist of two contact reeds
in a glass tube filled with inert gas. The field of a magnet causes the two reeds to close. Allowing
current to flow. In reed switches that act as normally closed contacts, the contact reeds are
closed by small magnets. This magnetic field is overcome by the considerably stronger magnetic
field of the switching magnets.
Reed switches have a long service life and a very short switching time (approx.0.2 ms). They are
maintenance-free, but must not be used in environments subject to strong magnetic fields (for
example in the vicinity of resistance welders).
Electronic sensors
Inductive, optical and capacitive proximity switches are electronic sensors. They normally have
three electrical contacts.
*
*
*
[ 28 ]
ELECTRO PNEUMATICS
VMPT-302 LC
In these sensors, no movable contact is switched instead, the output is either electrically
connected to the supply voltage or to ground (= output voltage 0V).
Positive and negative switching sensors
There are two types of electronic sensor with regard to the polarity of the output voltage.
*
In positive switching sensors, the output voltage is zero if no part is detected in the
proximity. The approach of a workpiece or machine part leads to switch over of the
output, applying the supply voltage.
In negative switching sensors, the supply voltage is applied to the output if no part is
detected in the proximity. The approach of a workpiece or machine part leads to switch
over of the output, switching the output voltage to 0V.
[ 29 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Symbol
Metal
Schematic diagram
Oscillator (1)
Flip-flop (2)
3
Amplifier (3)
[ 30 ]
ELECTRO PNEUMATICS
3.8
VMPT-302 LC
A capacitive proximity sensor consists of a capacitor and an electrical resistance that together
form an RC oscillator, and a circuit for evaluation of the frequency. An electrostatic field is
generated between the anode and the cathode of the capacitor.
A stray field forms at the front of the sensor. If an object is introduced into this stray field forms
at the front of the sensor. If an object is introduced into this stray field, the capacitance of the
capacitor changes. The oscillator is attenuated. The circuitry switches the output.
Capacitive proximity sensors not only react to highly conductive materials ( such as metal) but
also to insulators of high dielectric strength (such as plastics, glass, ceramics, fluids and wood).
Symbol
Schematic diagram
Oscillator (1)
Flip-flop (2)
3
Amplifier (3)
[ 31 ]
ELECTRO PNEUMATICS
VMPT-302 LC
3.9
In the mechanically actuated pressure switch, the pressure acts on a cylinder surface. If the
pressure exerted exceeds the spring force of the return spring, the piston moves and operates the
contact set.
Fig. 3.9:
piston-actuated
pressure switch
[ 32 ]
ELECTRO PNEUMATICS
3.10
VMPT-302 LC
Construction of a relay
A relay is an electromagnetically actuated switch. When a voltage is applied to the solenoid
coil, an electromagnet field results. This causes the armature to be attracted to the coil core. The
armature actuates the relay contacts, either closing or opening them, depending on the design.
A return spring returns the armature to its initial position when the current to the coil is
interrupted.
1.
2.
Coil core
Return spring
3.
4.
Relay coil
Amature
5.
6.
Insulation
Contact
[ 33 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Applications of relays
In electro pneumatic control systems, relays are used for the following functions:
*
Signal multiplication
Association of information
In purely electrical controllers, the relay is also used for isolation of DC and AC circuits.
Retentive relay
The retentive relay responds to current pulses:
*
If no input signal is applied, the previously set switch position is retained (retention).
The behavior of a retentive relay is analogous to that of a pneumatic double pilot valve, which
responds to pressure pulses.
Construction and mode of operation
Electrically actuated directional control valves are switched with the aid of solenoids. They can
be divided into two groups:
*
Spring-return valves only remain in the actuated position as long as current flows through
the solenoid.
Double solenoid valves retain the last switched position even when no current flows
through the solenoid.
[ 34 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Initial position
In the initial position all solenoids of an electrically actuated directional control valve are deenergized and the solenoids are inactive. A double solenoid valve has no clear initial position, as
it does not have a return spring.
Port Designation
Directional control valves are also differentiated by the number of ports and the number of
switching position. The valve designation results from the number of ports and positions, for
example:
*
The following section explains the construction and mode of operation of the major types of
valve.
3.11
Fig. 3.11 shows two cross-sections of a directly controlled electrically actuated 3/2-way valve.
*
In its initial position, the working port 2 is linked to the exhaust port 3 by the slot in the
armature (see detail) (fig. 3.11a).
If the solenoid is energized, the magnetic field forces the armature up against the pressure
of the spring (Fig.3.11b). The lower sealing seat opens and the path is free for flow from
pressure port 1 to working port 2. The upper sealing seat closes, shutting off the path
between port 1 and port 3.
If the solenoid coil is de-energized, the armature is retracted to its initial position by the
return spring (Fig. 3.11a). The path between port 2 and port 3 is opened and the path
between port 1 and port 2 closed. The compressed air is vented via the armature tube at
port 3.
[ 35 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Manual override
The manual override a allows the path between port 1 and port 2 to be opened even if the
solenoid is not energized. When the screw is turned, the eccentric cam actuates the armature.
Turning the screw back returns the armature to its initial position.
3.11a
3.12
3.11a
Fig. 3.12 shows an electrically actuated 3/2-way valve, normally open. Fig.3.12a shows the valve
in its initial position, Fig. 3.12b actuated. Compared to the initial position of the closed valve (fig.
3.12) the pressure and exhaust ports are reversed.
[ 36 ]
ELECTRO PNEUMATICS
VMPT-302 LC
In pilot controlled directional control valves, the valve piston is indirectly actuated.
*
If the armature is open, compressed air form port 1 actuates the valve piston.
If the coil is de-energized, the armature is pressed against the lower sealing seat by the
spring. The chamber of the upper side of the piston is vented(Fig. 3.13a).
If the coil is energized, the solenoid pulls the armature down. The chamber on the upper
side of the piston is pressurized (Fig. 3.13b)
[ 37 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Fig. 3.14 shows two cross-sections of an electrically actuated pilot controlled 3/2-way valve.
*
*
In its initial position, the piston surface is only subject to atmospheric pressure, so the
return spring pushes the piston up (Fig. 3.14a, b) Ports 2 and 3 are connected.
If the solenoid coil is energized, the chamber below the valve piton is connected to
pressure port 1. The force on the upper surface of the valve piston increases, pressing the
piston down. The connection between ports 2 and 3 is closed, the connection between
ports 1 and 2 opened. The valve remains in this position as long as the solenoid coil is
energized.
If the solenoid coil is de-energized, the valve switches back to its initial position.
A minimum supply pressure (control pressure) is required to actuate the pilot controlled valve
against the spring pressure. This pressure is given in the valve specifications and lies-depending
on type - in the range of about 2 to 3 bar.
[ 38 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Fig. 3.15 shows the two switching positions of an electrically actuated pilot controlled 5/2-way
valve.
*
In its initial position, the piston is at the left stop (fig.3.15a). Port 1 and 2 and ports 4 and
5 are connected.
If the solenoid coil is energized, the valve spool moves to the right stop (Fig. 3.15b). In
this position, ports 1 and 4 and 2 and 3 are connected.
If the solenoid is de-energized, the return spring returns the valve spool to its initial
position.
[ 39 ]
ELECTRO PNEUMATICS
Fig. 3.15
VMPT-302 LC
[ 40 ]
ELECTRO PNEUMATICS
3.16
VMPT-302 LC
Fig. 4.8 shows the three switching positions of an electrically actuated, pilot controlled 5/3-way
valve.
In its initial position, the solenoid coils are de-energized and the piston spool is held in the
mid-position by the two springs (Fig4.8a). Ports 2 and 3 and 4 and 5 are connected. Port
1 is closed.
If the left solenoid coil is energized, the piston moves to its right stop (Fig.4.8b). Ports 1
and 4 and 2 and 3 are connected.
If the right solenoid coil is energized, the piston moves to its left stop (Fig.4.8c). In this
position, ports 1 and 2 and 4 and 5are connected.
If neither coil is
[ 41 ]
ELECTRO PNEUMATICS
VMPT-302 LC
[ 42 ]
ELECTRO PNEUMATICS
VMPT-302 LC
CHAPTER - 4
COMPONENTS LIST OF PNEUMATIC PANEL
[ 43 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Types of compressor
4.1
Air Compressor
The selection from the various types compressors available in dependent upon quality of air,
pressure, quality and cleanliness and how dry the air should be. There are varying levels of these
criteria depending on the types of compressor.
Types of
compressor
Reciprocating
piston compressor
Piston compressor
Rotary piston
compressor
Diaphragm
compressor
Sliding vane
compressor
Flow compressor
Axial-flow
compressor
Radial-flow
compressor
Twin-shaft screw
compressor
Roots
compressor
(4 bar)
Single stage
[ 44 ]
ELECTRO PNEUMATICS
VMPT-302 LC
up to 1500 kPa
(15 bar)
Double stage
(> 15 bar)
Also, it is possible but not necessarily economic to operate in the following ranges:
up to 1200 kPa
(12 bar)
Single stage
up to 3000 kPa
(30 bar)
Double stage
(> 30 bar)
Diaphragm Compressor
The diaphragm compressor belongs to the reciprocating piston compressor group. The
compressor chamber is separated from the piston by a diaphragm. The advantage of this is that
no oil can enter into the air flow from the compressor. The diaphragm compressor is therefore
used where oil is to be excluded from the air supply, for example in the food, pharmaceutical and
chemical industries.
Rotary piston compressor
The rotary group of compressors use rotating elements to compress and increase the
pressure of the air. During the compression process, the compression chamber is continually
reduced.
Screw compressor
Two screw-shaped shafts (rotors) turn in opposite directions. The meshed profile of the
two shafts causes the air to flow which is then compressed.
Flow compressor
These are particularly suitable for large delivery quantities. Flow compressors are made
in axial or radial form. The air is made to flow by means of one or several turbine wheels. The
kinetic energy is converted into pressure energy. In the case of an axial compressor, the air is axial
compressor, the air is accelerated in the axial direction of flow by means of blades.
[ 45 ]
ELECTRO PNEUMATICS
4.2
VMPT-302 LC
List of components
However, the use of a lubricator does not need to be provided for in the power section of a
control system unless necessary, since the compressed air in the control section does not
necessarily need to be lubricated.
The correct combination, size and type of these elements are determined by the application and
the control system demand. An air service unit is fitted at each control system in the network to
ensure the quality of air for each individual task.
Compressed air filter
The compressed air filter has the job of removing all contaminants from the compressed
air flowing through it as well as water which has already condensed. The compressed air enters
the filter bowl through guide slots. Liquid particles and larger particles of dirty are separated
centrifugally collection in the lower part of the filter bowl. The collected condensate must be
drained before the level exceeds the maximum condensate mark, as it will otherwise be reentrained in the air stream.
The purpose of the regulator is to keep the operating pressure of the system (secondary pressure)
virtually constant regardless of fluctuations in the line pressure (primary pressure) and the air
consumption.
Compressed air lubricator
The purpose of the lubricator is to deliver a metered quantity of oil mist into a leg of the
distribution system when necessary for the operation of the pneumatic system.
[ 46 ]
ELECTRO PNEUMATICS
4.3
VMPT-302 LC
This valve consists of three ports and two states. The valve is controlled by a push button and
spring force. When the push button is depressed, the internal piston moves, allowing pressurized
air to pass from ports P to A. At this stage the valve is active. Upon release of the push button,
the spring force moves the internal piston, there by terminating the air flow from ports P to A, and
returns to the initial position. Air from port A is exhausted through port R.
[ 47 ]
ELECTRO PNEUMATICS
VMPT-302 LC
[ 48 ]
ELECTRO PNEUMATICS
VMPT-302 LC
[ 49 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Manifold
The manifold conducts pressurized air flow from the main pressure line and distributes it
to the various components connected to it. Generally Port A is the port used for the inlet of
pressurized air flow from the input component. The rest Ports B, C, D, and E are used to direct
pressurized air to the components. There is no restriction on the component that certain port
should act as inlet, it is user choice that any port can be used as inlet and rest as outlets.
A
[ 50 ]
ELECTRO PNEUMATICS
VMPT-302 LC
CHAPTER - 5
APPLICATION AND SYMBOLS FOR
DIRECTIONAL CONTROL VALVES
[ 51 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Symbol
Valve type
Applications
2
Shut-off function
12
1
2
Single-acting cylinders
12
3
Switching compressed
air on and off
10
3
14
3
1
4
Double-acting linear
or swivel cylinders
14
5
3
1
14
12
5
1 3
14
12
5
exhausted or pressurized)
1 3
14
12
5
1 3
Double-acting linear
or swivel cylinders
with intermediate
stop, with special
requirements regarding
behavior in event of
power failure.
14
12
3
Double-acting linear
or swivel cylinders
4
2
12
14
3
5
1
[ 52 ]
ELECTRO PNEUMATICS
VMPT-302 LC
CHAPTER - 6
PERFORMANCE DATA OF SOLENOID COILS
[ 53 ]
ELECTRO PNEUMATICS
6.1
VMPT-302 LC
An electrically actuated directional control valve can be equipped with various different solenoid
coils. The valve manufacturer usually offers one or more series of solenoid coils for each type of
directional control valve, with connection dimensions to match the valve. The choice of solenoid
coil is made on the basis of the electrical performance data (Table 4.4)
Coil type
DC Voltage
AC Voltage
Voltages Normal
Special
12V,24V,42V,48V
on request
Voltage fluctuation
Max.10%
Max.10%
Frequency fluctuation
Pickup : 7.5VA
Hold : 6VA
Power factor
0.7
Duty cycle
100%
100%
Degree of protection
IP65
IP 65
PG9
PG9
Ambient temperature
5 - 40C
Medium temperature
10 - 60C
10 - 60 C
The voltage specification in Table 4.4 relates to the voltage supplied to the solenoid coils. The
solenoid coils are chosen to match the signal control section of the electro pneumatic control
system. If the signal control section operates with a DC voltage of 24V, for example, the
corresponding type of coil should be chosen.
To ensure proper operation of the solenoid coil, the voltage supplied to it from the signal control
section must be within certain limits for the 24V coil type, the limits are as follows:
Minimum Voltage : Vmin = 24V. (100% - 10%) = 24V.0.9 = 21.6V
Maximum Voltage : Vmax = 24V. (100% + 10%) = 24V.1.1 = 26.4V
If the signal control section operates with Ac voltage and there fore AC solenoid coils are used,
[ 54 ]
ELECTRO PNEUMATICS
VMPT-302 LC
the frequency of the AC voltage must be within a specified range. For the AC coils described in
the table, frequencies up to 5% above or below 50Hz are permissible; in other words the
permitted frequency range is between 47.5 and 52.5 Hz.
6.3
The solenoid coil of a directional control valve if connected to the signal control section of an
electro pneumatic control system via a two-core cable.
There is a removable plug connector between the cable and the solenoid. When the connector
is inserted it is screwed down to protect the plug contacts against the ingress of dust and water.
The type of plug connector and cable conduit fitting are specified in the technical documentation
for the solenoid coil (such as PG9 in table 4.4)
6.4
The electric circuit is opened or closed by a contact in the signal control section of the control
system. When the contact is opened, the current through the solenoid coil suddenly decays. As
a result of the rapid change in current intensity, in conjunction with the inductance of the coil, a
very high voltage is induced briefly in the coil. Arcing may occur at the opening contact. Even
after only a short operating time, this leads to destruction of the contact. A protective circuit is
therefore necessary.
Fig. 4.13 shows the protective circuit for a DC coil. While the contact is closed, current I1 flows
through the solenoid and the diode is de-energized (fig. 6.4 a). When the contact is opened, the
flow of current in the main circuit is interrupted (Fig. 6.5b). The circuit is now closed via the
diode. In that way the current can continue flowing through the coil until the energy stored in
the magnetic field is dissipated.
As a result of the protective circuit, current IM is no longer subject to sudden decay, instead it
is continuously reduced over a certain length of time the induced voltage peak is considerably
lower, ensuring that the contact and solenoid coil are not damaged.
[ 55 ]
ELECTRO PNEUMATICS
VMPT-302 LC
i1
IM = I1
ID =0
IM
ID=IM
+24V
0V
i1= 0
+24V
0V
[ 56 ]
ELECTRO PNEUMATICS
6.5
VMPT-302 LC
The protective circuit and auxiliary functions are integrated either into the cable socket or in the
form of adapter inserts i.e. illuminating seal (Fig. 4.14). Appropriate adapters and cable sockets
must be chosen to match the voltage at which the signal control section operates (for example
24V DC).
[ 57 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Class of protection
Plugs, sockets and adapters are sealed in order to prevent either dust or moisture from entering
the plug connection. If the adapter, solenoid coil and valve have different classes of protection,
the lowest of the three classes of protection applies to the assembled valve, coil and cable conduit.
Explosion protection
If it is intended to use electrically actuated directional control valves in an environment subject
to explosion hazards, special solenoid coils approved for sch applications are required; these have
molded cables.
[ 58 ]
ELECTRO PNEUMATICS
VMPT-302 LC
CHAPTER - 7
APPLICATION OF ELECTRO PNEUMATIC
SYSTEM
[ 59 ]
ELECTRO PNEUMATICS
VMPT-302 LC
A lifting device transfers work pieces from the one roller conveyor or to another a different
height. The task is to carry out the project engineering for the associated electro pneumatic
control system.
A positional sketch of the lifting device is shown in fig. 5.2. There are three pneumatic drives;
*
Drive 3A is used as a stopper, for releasing and interrupting this supply of workpieces.
[ 60 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Note
The packages first have to be separated to be fed singly; this is done at an upstream facility. The
optical proximity switch B6 is not taken into account for the purposes of further project
engineering of the lifting device.
7.1
Cylinder 1A requires a stroke of 500mm and a force of at least 600N, cylinder 2A a stroke of
250mm and a force of at least 400 N. Cylinder 3A requires a stroke of 20 mm and a force of
40N. On cylinders 1A and 2A the advance and retract speeds of the piston rods need to be
variable. The control system must allow soft braking of drives 1A and 2A.
To prevent the possibility of secondary damage, in the event of an electrical power failure the
piston rods for cylinders 1A and 2A are to be braked immediately and remain at a standstill. The
piston rod of the stopper cylinder 3A is meant to extend in these circumstances.
Movement cycle of the lifting device
The movement cycle of the lifting device is described in Table 5.2 (see positional sketch, Fig. 5.2).
It comprises four steps.
Step
Movement piston
rodcylinder A
Movement piston
rodcylinder 2A
Movement piston
rodcylindr 3A
comments
None
None
Retract
B5 triggered (package
present)
Open device
Advance
None
Advance
1B2 triggered
Lift package
None
Advance
None
2B2 triggered
Push out
package
Retract
Retract
None
Retract drives to
initial position
[ 61 ]
ELECTRO PNEUMATICS
7.2
VMPT-302 LC
Operator Control
The control system of the lifting device must enable the device to be run in a continuous cycle
(continuous operation). A single cycle operating mode is also necessary in which the sequence
is processed precisely once.
The operator control equipment for the system must conform to the relevant standards (see
section 7.4). The control panel for the lifting device is shown in Fig.5.3.
The following operating functions are specified in more detail in relation to the lifting device:
*
*
*
EMERGENCY STOP: When this is actuated, not only the electrical power supply, also
the pneumatic power supply must be shut down.
Reset : This returns the system to the initial position, i.e, the piston rods of cylinders 1A
and 2A retract, the piston rod of cylinder 3A extends.
Continuous cycle OFF: This stops the continuous cycle process. If there is already a
workpiece in the device, it is transferred to the upper roller conveyor. The piston rods of
cylinders 1A and 2A retract. The device is subsequently in its initial position.
EMERGENCY STOP
Main switch
EMERGENCY STOP
Continous
cycle on
Single
cycle start
Automatic
Continous
cycle off
Manual
Reset
[ 62 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Ambient conditions
The lifting device is used in a production shop in which the temperature fluctuates between 15 and
35 degrees centigrade. The pneumatic components of the power section and the electrical
connections of the valves are to be dust-tight and splash-proof. The electrical components of the
signal control section are installed in a control cabinet and must conform to the relevant safety
regulations.
Power supply
The following power supply networks are available:
*
The electrical signal control section and the main circuit are to be operated with 24V DC. A
power supply unit therefore needs to be provided to supply this voltage.
7.3
The signal processing aspect of the lifting device is implemented as a relay control system. In
view of the small number of drive units, the valves are mounted separately.
As the linear guides of the lifting platform and of the pushing device are already part of the
station, cylinders without integrated guides are used. Double-acting cylinders are used for drives
1A and 2A. Drive 3A takes the form of a single - acting stopper cylinder.
Selection of cylinders
The cylinders are chosen on the basis of the requirements in terms of force and stroke, using
catalogues obtained from pneumatics manufacturers. On account of the required drive force,
cylinder 1A must have a piston diameter of at least 40mm, and cylinder 2A a piston diameter of
at least 40mm, and cylinder 2A a piston diameter of at least 32mm.
To ensure soft braking, cylinders with integrated adjustable end position cushioning are used for
drives 1A and 2A. The following cylinders would be suitable, for example:
*
A stopper cylinder is used for drive 3A; it is extended if the compressed air supply fails. This
requirement is met by a Festo STA-32-20-P-A type cylinder, for example
[ 63 ]
ELECTRO PNEUMATICS
VMPT-302 LC
[ 64 ]
ELECTRO PNEUMATICS
Drive/
function
VMPT-302 LC
Actuated solenoid
Control
Element
Proximity switch
Advance
Retract
Cyl.1A
1M1
1M2
1B2
1B1
Control chain 1
Cyl.2A
2M1
2M2
2B2
2B1
Control chain 2
3M1
3B1
Cyl.3A
Comp.air
Other
Advance
Retract
Comments
Other
Control chain 3
Pressure sequence valve
0M1
B5
Main switch
S2
S3
Manual (MAN)
S4
Automatic (AUT)
S5
Reset
S6
Continous cycle ON
S7
S8
[ 65 ]
ELECTRO PNEUMATICS
7.4
VMPT-302 LC
The displacement-step diagram for the lifting device is shown in Fig. 5.4. it illustrates the steps
in which the piston rods of the three cylinders advance and retract, and when the proximity
switches respond.
S4 (AUT)
S6
S7
1B1 ^ 2B1 ^ 3B1
B5
1
5=1
1
1B2
Cylinder 1A
1B1
0
2B2
1
Cylinder 2A
2B1
0
1
3B1
Cylinder 3A
0
[ 66 ]
ELECTRO PNEUMATICS
VMPT-302 LC
CHAPTER - 8
SAFETY MEASURES FOR ELECTRO
PNEUMATIC CONTROL SYSTEMS
[ 67 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Numerous protective measures are necessary in order to ensure that electro pneumatic control
systems can be safely operated.
One source of danger is moving parts of machines and equipment. On a pneumatic press, for
example, care must be taken to prevent the operators fingers or hands from being trapped. Fig
8.0 provides an overview of sources of danger and suitable protective measures.
Fig.8.0 Moving parts of machines and equipment: sources and danger and protective
measures
8.1
Source of danger
Electric current is another source of danger. The dangers and protective measures relating to
Protection by
enclosure/covering
Cage
Grid
Protection by
control and
signalling devices
Warning lights
EMERGENCY STOP
Two-hand safety control
Protection by
signal processing
measures
Protection against
unsupervised startup
Setup procedure
[ 68 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Protection against
contact with high
voltage
Safety extra-low
voltage
Covering/housing
Adequate distance
Grounding
8.2
Protection during
maintenance and
repair work
Main switch with
interclocking
Protection of
electrical equipment
against environmental
influences
Protection against
dust/foreign bodies
Protection against
water/moisture
Safety rules
In order to provide the best possible safeguards for operating personnel, various safety rules and
standards must be observed when designing electro pneumatic control systems. The key standards
dealing with protection against the dangers of electric current are listed below.
*
Protection measures for Electrical Power Installations up to 1000V (DIN VDE 0100).
When a person touches a live part, an electric circuit is completed. An electric current flows
through the persons body.
[ 69 ]
ELECTRO PNEUMATICS
8.3
VMPT-302 LC
The effect of electric current on the human body increases with the intensity of the current and
with the length of time in contact with the current. The effects are grouped according to the
following threshold values.
*
Below the threshold perception, electric current has no effect on the human body to
human health.
Above the let-go threshold muscles become cramped and functioning of the heart is
impaired.
Above the threshold of non-fibrillation, the effects are cardiac arrest or ventricular.
Up to the let-go threshold, electric current is perceived but there is no danger fibrillation,
cessation of breathing and unconsciousness. There is an acute risk to life.
The threshold of perception, let-go threshold and non-fibrillation threshold are plotted in fig for
alternating current with a frequency of 50 Hz. This corresponds to the frequency of the electrical
supply network. For direct current, the threshold values for endangering human beings are slightly
higher.
Electrical resistance of the human body
The human body offer resistance to the flow of current. Electric current may enter the body
through the hand, for example: it then flows through the body to reemerge at another point (such
as the feet-see fig). Accordingly, the electrical resistance RM of the human body (Fig ) is formed
by a series circuit comprising the entry resistance R01 the internal resistance R1 and the exit
resistance R02 (Fig ). It is calculated using the following formula:
RM R01 R1 R02
The contact resistances R01 and R02 vary greatly depending on the contact surface and the
moistness and thickness of the skin. This affects the total resistance RM. It may range between
the following extremes.
*
Less than 1000 ohms (large contact surfaces, wet, sweaty skin)
[ 70 ]
ELECTRO PNEUMATICS
VMPT-302 LC
I
G
~
R01
R1
R02
I
RL
G
~
RM
RM
U
~
RE
[ 71 ]
ELECTRO PNEUMATICS
8.4
VMPT-302 LC
The current I through the human body is dependent on the source voltage V, the resistance RL
of the electric line, the resistance RM of the person and the resistance RE of the ground (Fig). It
is calculated as follows:
V
RL R M RE
According to this formula, a high current, i.e. a high level of danger, is obtained in the following
circumstances:
*
10000
5000
ms
2000
Threshold of
non-fibrillation
Threshold of
perception
1000
500
Time t
Let-go
threshold
200
100
50
20
10
0
0.1
0.2
0.5
10
20
50
100
200
500
mA
2000
Current I
[ 72 ]
ELECTRO PNEUMATICS
VMPT-302 LC
CHAPTER - 9
COMPONENTS DESCRIPTION OF ELECTRO PNEUMATIC
TRAINER
[ 73 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Design: Pop pet valve, directly actuated, one side with return spring.
Pressure range: (-0.9 to 8 bar)
Nominal flow rate 12: 80 l/min.
Nominal flow rate 1 .. 4: 500 l/min.
Response time: Optimum.
[ 74 ]
ELECTRO PNEUMATICS
*
*
*
*
VMPT-302 LC
[ 75 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Filter control valve with pressure gauge, start-up valve, quick push-pull connectors and
quick couplings, mounted on a swivel support.
The filter with water separator removes dirt, pipe sinter, rust and condensed water.
The pressure control valve regulates the supply air pressure to the set operating pressure
and compensates pressure fluctuations. The filter bowl has a condensate drain valve.
The start-up valve / shut off valve ventilates and vents the entire control. The 3/2 way
valve is actuated by a rotary button.
Design Sintered filter
Nominal flow rate 750 l/min
Input Pressure Maximum (16 bar)
Output pressure Maximum (12 bar)
Grade of filtration 40 m
Condensate quantity 22 c.cm.
Connector G 1/8
[ 76 ]
ELECTRO PNEUMATICS
VMPT-302 LC
[ 77 ]
ELECTRO PNEUMATICS
VMPT-302 LC
[ 78 ]
ELECTRO PNEUMATICS
VMPT-302 LC
CHAPTER - 10
EXPERIMENTAL SECTION
[ 79 ]
ELECTRO PNEUMATICS
VMPT-302 LC
[ 80 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 1
CIRCUIT DIAGRAM
2
1
1
AND Gate
1
3/2 Push button valve
1
3/2 Push button
Component Description
FRL
Number
Compressor
Description
[ 81 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 1
CONTROL THE SINGLE ACTING CYLINDER USING
TWO WAY PRESSURE VALVE
Aim
To construct a pneumatic circuit to control the single acting cylinder control by Two-way
pressure valve.
Apparatus Required
Compressor air
FRL
Two-way pressure valve
Single acting cylinder
Procedure
1.
2.
3.
4.
5.
6.
7.
Truth table
Input 1
Input 2
Output
ON
OFF
OFF
ON
ON
OFF
ON
OFF
ON
OFF
OFF
OFF
Result
The pneumatic circuit of two way pressure valve was simulated.
[ 82 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 2
CIRCUIT DIAGRAM
2
1
1
OR Gate
1
3/2 Push button valve
1
3/2 Push button
Component Description
FRL
Number
Compressor
Description
Shuttle valve
[ 83 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 2
FOR USING OR GATE CONTROL TO SINGLE ACTING CYLINDER
Aim
To construct a pneumatic circuit to control the single acting cylinder.
Apparatus Required
Compressor air
Tube
3/2 push button valve
Shuttle valve
Single acting cylinder
Procedure
1.
2.
3.
Any two of the output of FRL unit to first 3/2 push button valve inlet and second 3/2
push button valve inlet.
4.
Both 3/2 push button valves outputs to give shut the valve inlet ports.
5.
6.
Open the hand slide valve. The air passes in both 3/2 push button valve inlets.
7.
Press any one push button valve. The cylinder will be activated.
Truth table
Input 1
Input 2
Output
OFF
ON
OFF
ON
OFF
OFF
ON
ON
OFF
ON
ON
ON
Result
Thus the single acting cylinder controlled by OR Gate.
[ 84 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 3
CIRCUIT DIAGRAM
1 3
5/2 Single pilot valve
3
3/2 Push button valve
Component Description
Number
FRL
Compressor
Description
[ 85 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 3
FOR USING 5/2 SINGLE PILOT VALVE, CONTROL TO
DOUBLE ACTING CYLINDER
Aim
To construct a pneumatic circuit to control the single acting cylinder.
Apparatus Required
Compressor air
FRL
3/2 Push button valve
5/2 single pilot valve
Air tube
Procedure
1.
2.
3.
Connect any one of the outputs o FRL unit to 5/2 single pilot valve inlet port 1.
4.
Again one of the outputs of FRL unit to connect to any to 3/2 push button valve inlet.
5.
3/2 push button valve output connect to 5/2 double pilot valve (port 12).
6.
Both outputs of 5/2 double valve directly connected to double acting cylinder.
7.
When is press 3/2 push button valve the cylinder will be activated.
Result
The direct control of a double acting cylinder was simulated.
[ 86 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 4
CIRCUIT DIAGRAM
3
5/2 Double pilot valve
3
3/2 Push button valve
Component Description
Number
FRL
Compressor
Description
Compressed air supply
[ 87 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 4
DOUBLE ACTING CYLINDER CONTROL BY
USING 5/2 DOUBLE PILOT VALVE
Aim
To construct a pneumatic circuit to control the double acting cylinder using 5/2 double pilot
valve.
Apparatus required
Compressor
Air tube
3/2 push button valve
5/2 double pilot valve
FRL unit
Procedure
1.
2.
3.
Two outputs of FRL unit directly connected to 3/2 push button valves inlets. The both
outputs connected to double pilot (Port 12, Port 14).
4.
3/2 double pilot outputs (2, 4) are connect to double acting cylinder.
5.
6.
Result
Thus the double acting cylinder controlled by 5/2 double pilot valve.
[ 88 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 5
CIRCUIT DIAGRAM
W1
W2
Double acting
cylinder
W2
W1
Component Description
FRL
Compressor
Number Description
1
Compressor
1
[ 89 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 5
CONTINUOS RECIPROCATING OF DOUBLE ACTING CYLINDER CONTROL
THE 5/2 DOUBLE PILOT VALVE
Aim
To construct a circuit to control the forward return stroke of a double acting cylinder by pilot
pressure.
Apparatus required
Air compressor.
Air tube.
Double acting cylinder.
3/2 roller lever valve.
5/2 double pilot valve and flow control valve.
Procedure
1.
2.
3.
Connect any one of the outputs of FRL unit to 5/2 direction control unit port 1.
4.
5.
Connect the output of FRL unit to the input of two 3/2 roller lever valves to give pilot
pressure for 5/2 double pilot valve.
6.
The output of the two roller valves are connected to the either side of the 5/2 double pilot
valve properly.
7.
When the FRL valves is opened the higher pressure air enters the blank end of the cylinder
through DCT and the piston moves forward.
8.
At the end of the forward stroke the piston rod pressure the roller valve. The output of
roller valve is sent to double acting cylinder to change the position.
9.
Now the high pressure air from FRL unit is sent to rod end of the double acting cylinder
through the second position of the DCV the piston retracts.
10.
At the end of the return stroke the roller valve is pressed. The output of the roller valve
is sent to DC change the piston. This is repeated until the FRL valve is closed.
Result
The continuos reciprocating of double acting cylinder was simulated.
[ 90 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 6
CIRCUIT DIAGRAM
3
W1
W2
Double acting
cylinder
W3
W2
W3
FRL
Compressor
Component Description
Number Description
1
Compressed air supply
Distance rule
[ 91 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 6
STUDY THE CIRCUIT USING (A+B-A-B)
Aim
To design a circuit for the sequence A+B-A-B.
Apparatus Required
Compressor
FRL
5/2 Double pilot valve
Single acting cylinder
Double acting cylinder
3/2 Roller lever valve.
Air tube
Procedure
1.
2.
3.
4.
5.
6.
Result
The circuit diagram for the sequence is drawn and executed.
[ 92 ]
ELECTRO PNEUMATICS
VMPT-302 LC
[ 93 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Mechanical Circuit
Electrical Circuit
24V
14
2
S1
1
Solenoid coil
S1
3/2 Single solenoid valve
FRL
0V
Compressor
Material Description
Number
Description
Electrical connection 0V
Pushbutton (make)
Valve solenoid
[ 94 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 1
Controlling the single acting cylinder using electrically.
AIM
To construct a pneumatic circuit to control the single acting cylinder electrically using push button
switch.
APPARATUS REQUIRED
Compressor, FRL, solenoid coil, electrical trainer, single acting cylinder and batch card.
PROCEDURE
1.
2.
3.
4.
5.
6.
7.
Observe the working of the cylinder using the 3/2 single solenoid valve.
Result
Thus the movement of single acting cylinder was carried out using the 3/2 single solenoid valve.
[ 95 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Mechanical Circuit
Electrical Circuit
24V
24V
SPDT
2
W1
W1
W2
solenoid coil
5
1
W2
FRL
0V
0V
Compressor
Material Description
Number
SPDT -
Description
Pushbutton (make)
Electrical connection 0V
Valve solenoid
[ 96 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 2
Actuation of double acting cylinder using 5/2 double solenoid valve through SPDT switch.
AIM
To develop a electro pneumatic circuit to actuate a double acting cylinder.
APPARATUS REQUIRED
Compressor, FRL, Electrical controller, 5/2 Double solenoid valve, SPDT switch and Data Card.
PROCEDURE
1.
Provide power supply to the pneumatic trainer from control trainer by interfacing 24V +
and -
2.
Using the SPDT switch energize the corresponding solenoid valve to get the desired
movement in the cylinder.
3.
4.
5.
6.
7.
8.
Observe the working of the cylinder using the 5/2 double solenoid valve.
Result
Thus the movement of the double acting cylinder was carried out using the 5/2 DCV.
[ 97 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Electrical circuit
Mechanical circuit
+24V
1
3
W1
5
5/2 Single pilot valve
W1
Solenoid coil
FRL
0V
Compressor
Material Description
Designation
Description
Pushbutton (make)
Electrical connection 0V
Valve solenoid
[ 98 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 3
Electrically control Double acting cylinder using pushbutton switch.
AIM
To construct a pneumatic circuit to control the single acting cylinder electrically using push button
switch.
APPARATUS REQUIRED
Compressor, FRL, 5/2 Double solenoid valve, electrical trainer, single acting cylinder and Batch
card.
PROCEDURE
1.
Draw the circuit diagram and connect the air supply to FRL unit.
2.
3.
4.
When the solenoid is given a signal by a push button switch. DCV is activated to double
acting cylinder.
5.
When off button is pressed the signal solenoid are cut and the solenoids are de-energized
and the DCV comes to the original position.
RESULT
Thus the double acting cylinder is controlled electrically operated switch.
[ 99 ]
ELECTRO PNEUMATICS
VMPT-302 LC
24V
3
3
3
Push button switch
14
S1
2
Make switch
4
2
S1
On delay timer A1
T1
S1
A2
FRL
Solenoid coil
0V
Compressor
3
Material Description
Number
Description
Distance rule
Pushbutton (make)
Electrical connection 0V
Make switch
[ 100 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 4
Actuation of single acting cylinder using Time delay valve used to on delay timer.
AIM
To develop an electro pneumatic circuit for actuation of single acting cylinder using timer.
APPARATUS REQUIRED
Compressor Air, FRL, Time delay valve, electrical controller, single acting cylinder, 3/2 single
solenoid valve and Batch card.
PROCEDURE
1.
Provide power supply to electrical controller by interfacing the +ve to +ve and -ve to -ve.
2.
Provide power supply to pneumatic trainer from electrical controller by interfacing 24 +ve
to +ve and -ve to -ve.
3.
Using the SPDT switch energize the corresponding solenoid to get the desired movement
of the cylinder.
4.
5.
From dime delay give connection to single along cylinders to actual cylinder according to
time set.
6.
7.
8.
9.
Result
Thus the movement of single acting cylinder was carried out using time delay.
[ 101 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Mechanical Circuit
Electrical Circuit
24V
1
3
Push button switch
T1
Make switch
4
2
Off delay timer
T1
S1
A1
5
A2
S1
Solenoid coil
3
0V
FRL
Compressor
Material Description
Number
Description
Pushbutton (make)
Electrical connection 0V
Make switch
Valve solenoid
[ 102 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 5
Actuation of single acting cylinder using OFF delay Timer.
AIM
To develop an electro pneumatic circuit for actuation of a single acting cylinder using OFF delay
Timer.
APPARATUS REQUIRED
Compressor Air, FRL, 3/2single acting cylinder, electrical controller, single acting cylinder, Timer,
Batch chord.
PROCEDURE
1.
Provide power supply to pneumatic trainer from electrical controller by inter facing 24+
and 24-.
2.
3.
Any one of the output of FRL unit direct connect to 3/2 single solenoid valve.
4.
5.
6.
7.
8.
9.
Result
Thus the movement of single acting cylinder was carried out using time delay.
[ 103 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Mechanical Circuit
Q1
Q2
Material Description
4
Number
W1
W2
5
5/2 Double solenoid valve
Description
Compressor
FRL
1
1
1
3
1
FRL
Compressor
Electrical Circuit
+24V
Q1
Q2
Proximity
Sensor
W1
W2
Solenoid Coil
Solenoid Coil
0V
[ 104 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 6
Continuos actuation of double acting cylinder using magnetic proximity sensor.
AIM
To construct a pneumatic circuit to control the double acting cylinder electrically using magnetic
proximity sensor.
APPARATUS REQUIRED
Compressor Air, FRL, 5/2 double solenoid valve electrical controller, sensor, double acting
cylinder and flow control valve.
PROCEDURE
1.
2.
3.
4.
Connect the electrical circuit from electrical controller to panel [24+ and 24-)
5.
Connect from proximity sensor output to 5/2 double solenoid valve input.
6.
7.
8.
Result
Thus the movement of double acting cylinder was carried out using the magnetic proximity
sensor.
[ 105 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Mechanical Circuit
P1
P2
P3
P4
S1
S3
5
S2
S4
5
3
1
3
1
FRL
Compressor
Electrical Circuit
Material
+24V
3 4
Number
6 7
1
1
2
S1
S2
Solenoid coil
S3
S4
1
2
1
1
4
4
1
Description
Compressed air supply
Air service unit, simplified
representation
Double acting cylinder
5/2 Way valve
One-way flow control valve
5/2-way valve, with
selection switch
Electrical connection 0V
Pushbutton (make)
Valve solenoid
Electrical connection 24V
0V
Description
[ 106 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 7
Simulation of Electrically sequencing circuit using a double acting cylinder and miniature cylinder.
AIM
To simulate the electrically sequencing circuit using Push button switch.
APPARATUS REQUIRED
Compressor Air, FRL, 5/2 Double solenoid valve, electrical controller, double acting cylinder,
Miniature cylinder then batch card.
PROCEDURE
1.
2.
3.
4.
5.
6.
RESULT
Thus the sequence of double acting cylinders was carried out using push button switch.
[ 107 ]
ELECTRO PNEUMATICS
VMPT-302 LC
Mechanical Circuit
P1
P2
P3
P4
S1
S3
5
S2
S4
5
3
1
3
1
FRL
Compressor
Electrical Circuit
+24V 1
3
4
P3
P2
Proximity
Sensor
S1
S2
P1
Proximity
Sensor
P4
S4
S3
Solenoid Coil
0V
Number
1
1
2
1
2
1
1
1
4
4
2
Description
Compressed air supply
Air service unit, simplified
representation
Double acting cylinder
5/2 Way valve
One-way flow control valve
5/2-way valve, with
selection switch
Electrical connection 0V
Electrical connection 24V
Magnetic proximity switch
Valve solenoid
Distance rule
[ 108 ]
ELECTRO PNEUMATICS
VMPT-302 LC
EXPERIMENT - 8
AIM
Study the circuit A+B+A-B- using electrically magnetic sensor proximity.
APPARATUS REQUIRED
Compressor Air, FRL, electrical controller, double acting cylinder, 5/2 Double solenoid valve
Magnetic proximity switch, miniature cylinder.
PROCEDURE
1.
2.
Provide power supply to electrical controller by interfacing the 24+ve to +24ve and
negative voltage.
3.
Any one output is push button have direct connected to electro pneumatic panel +24V or
-24V. This push button should be on.
4.
5.
6.
7.
8.
Observe the working of the cylinders auto material reciprocating of circuit in A+B+A-B.
Result
Thus the movement of double acting cylinder were carried out using the circuit A+B+A-B.
[ 109 ]