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PNEUMATICS
It is a branch of physics that deals with
the study of gases especially air, its mechanical
properties and applications at pressures higher
(compressed) or lower (vacuum) than the
atmospheric pressure.
It comes from the
Pneuma meaning breath.
Greek
word
APPLICATIONS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Transportation
Feeder
Supply
Positioning
Clamping
Turning
Stamping
Bending
Hole boring
Handling
Assembly
Measuring
Service life testing
Signal-flow representation
Energy flow representation
HISTORY
The earliest pneumatic transmission
dates from 1700, when the French physicist
Denis Papin used power from a waterwheel to
compress air that was transmitted through
tubes.
About a century later the British
inventor George Medhurst received a patent to
use compressed air to drive a motor, although
credit for the first practical application was
given to the British inventor George Law, who
in 1865 devised the rock drill, in which an airdriven piston operated a hammer tool. The rock
drill was widely adopted and used in the
drilling of the Mont Cenis railroad tunnel in the
Swiss Alps, which opened in 1871, and for the
Hoosac tunnel in western Massachusetts, which
opened in 1875.
SIGNAL OUTPUT
Actuator Engineering
SIGNAL PROCESSING
Processor Techniques
SIGNAL INPUT
Sensory Analysis
Signal-Flow Diagram
Pneumatics Technology
ACTUATOR
Cylinder
DRIVE ELEMENT
Cylinder
SENSOR
Push-button
PROCESSOR
Directional
Control Valve
CONTROL
ELEMENT
SIGNALING
ELEMENT
Directional
Control Valve
Push-button
Pressure
Line
Pilot
Line
Air
Compressor
Electric
Motor
Practical Energy-Flow Pneumatic Setup
ENERGY
CONVERSION
Drive
Element
Energy Transfer
Controlling
Element
Actuator
Output
ENERGY
CONTROL
Signal
Input
Energy Transfer
Signaling
Element
ENERGY
CONVERSION
CONTROL ENERGY
( Pneumatic or Electrical )
WORKING ENERGY
( Electrical )
Pneumatic /
Mechanical
MACHINE, INSTALLATION
Drive Elements
Cylinders
Rotary actuators
Pneumatic
Compressed-Air Motors
Sub-assemblies
Actuators, Controlling Elements
and Signaling Elements
Directional-control valves
Flow-control valves
Check valves
Mechanical /
Pressure-control valves
Pneumatic
Air-service Units
Filters
Regulators
Lubricators
Pneumatics Technology
PNEUMATIC POWER SUPPLY
Pneumatic systems are powered with
compressed air. The source of compressed air is
the central compressed-air unit also known as
pneumatic power supply. The main devices
included in the pneumatic power supply are:
Compressor(s)
Suction Filter
Check Valve
Cooler
Filter with water trap
Reservoir
Pressure switch
Pressure relief valve
Pressure gauges
Thermometers
Hand-slide valve
Compressor head,
first stage
are
and
highly
mobile
Compressor head,
second stage
COMPRESSOR
The device that generates compressed air is
the compressor. It converts mechanical energy
to pneumatic energy of the compressed air.
Different types of compressors are known,
depending on their construction, as follows:
Piston compressors (single/two stages)
Screw-type (worm) compressors
Diaphragm-type compressors
Membrane compressors
Sliding-Vane rotary compressors
Helical compressors
Root compressors
Turbo (axial or radial flow) compressors
The most frequently used compressors are
piston
compressors
and
screw-type
compressors and both operate according to the
displacement principle. They are suitable for
pneumatic systems, where low, middle or high
air pressure is needed. Both compressor types
are designed for maximum delivery quantities
(volumetric flow) in the range from
approximately 30,000 to 40,000 m3 / h
Compressor
Cooler
Check Valve
Block
Typical picture of a Piston Compressor
Suction
Port
Suction
Valve
Pressure
Valve
Pressure
Port
Cooling
Ribs
Piston
Crank Shaft
Mechanism
Compressor
Block
Piston Compressor
( Standardized Symbol according to DIN ISO 1219 )
Pneumatics Technology
Mode of Operation
Suction
Port
Piston
Cylinder
Pressure
Port
Pressure
Valve
Suction
Valve
Compressed
Air
Drive
Shaft
Crank
Shaft
Pressure
Valve
Suction
Stroke
The top-most position, which the piston
may reach in the cylinder, is called the top dead
center (TDC). Similarly, the lower-most position
is called the bottom dead center (BDC). When
the piston moves from the TDC to the BDC the
pressure valve is closed. The atmospheric air
flows through the inlet suction valve into the
piston area. This motion of the piston is called
the suction stroke.
SUCTION FILTER
The suction filter partially cleans the air driven
in a pneumatic system. The suction filter is normally
place on the suction port of pneumatic compressors.
Suction Filter
CHECK VALVE
The check valve, also known as non-return
valve allows the compressed air to flow in only one
direction. It is normally fitted after the piston
compressor to protect the latter from receiving backflow
of compressed air.
Pneumatics Technology
COOLER
The cooler is a device which brings
down the temperature of the compressed air in
pneumatic systems. This is needed for the
normal operation of pneumatic systems.
Cooler
Reservoir
PRESSURE SWITCH
The pressure switch is an example of PE converter
because it controls the on and off switching state of the
electric motor that drives the piston compressor. It is
used to establish and maintain pressure in pneumatic
systems at a specified level by turning the electrical
motor off once the specified accumulated pressure is
achieved.
RESERVOIR
The reservoir also known as a pneumatic
capacitor or a pressure accumulator is a specific
accumulator of pneumatic energy. It is placed in
pneumatic systems to perform the following
basic functions:
Pressure Switch
Pneumatics Technology
Pressure Gauge
THERMOMETERS
Thermometers are devices that are inserted in
the pneumatic power supply to monitor the temperature
of the compressed air in pneumatic systems. This is
needed for maintaining the normal operation of
pneumatic systems.
HAND-SLIDE VALVE
Pressure Relief Valve
PRESSURE GAUGES
The pressure gauge is a device which
measures and indicates the operating pressure
at certain points in the pneumatic system. It is
used for the following main purposes:
Hand-slide Valve
Pneumatics Technology
PNEUMATIC POWER SUPPLY
DIAGRAM
Thermometer
Pressure
Gauge
Pressure-Relief
Valve
COMPRESSED-AIR ENERGY
Reservoir
Shut-off
Valve
Pressure
Switch
PE
Check
Valve
Cooler
Filter with
Water Trap
Compressor
Suction
Filter
= Absolute Pressure
= Ambient / Atmospheric
Pressure
= Gauge / Operating
/ Working Pressure
INHERENT PROPERTIES
IN PNEUMATIC ENERGY
Availability
Transportability
Storability
Environmental influences like dust, dampness
and temperature
Explosion hazard
Cleanliness
Working speed
Overload capacity
Working speed control
Energy cost
Energy preparation
Signal speed
Constant working movements
Forces and torques
Noise
Pneumatics Technology
COMPRESSEDAIR PREPARATION
AIR COMPRESSION
110
PRESSURE
INCREASES
TEMPERATURE
INCREASES
90
70
COOLING
WATER
VAPOR
DRYING
50
30
WATER
REMOVAL
DEW-POINT CURVE
The dew-point curve shows the airs
capacity for absorbing water in g/m3 as a
function of the air temperature.
The temperature at which the air cannot
hold all the moisture in it and dew begins to
form. If objects and surfaces have cooled to
below freezing point when the moisture in the
air begins to condense, frost is formed instead.
20
40
60
80
Degrees
Celsius
Dew-point Curve
COMPRESSEDAIR DRYING
AND COOLING METHODS
ABSORPTION DRYING
It is the chemical process in which the air flows
over a desiccant which binds the air and dissolves in the
process. A desiccant is a substance that absorbs water
and can be used to remove moisture.
The resulting condensate must be removed at
regular intervals and the desiccant renewed.
ADSORPTION DRYING
Adsorption is the process by which a layer of
atoms or molecules of a substance, usually a gas, is
formed on the surface of a solid or liquid.
In this process, the air is alternately switched
back and forth by means of check valve control between
two containers which are filled with a desiccant which
absorbs the water vapor. Hot air is then blown through
the wt desiccant to dry it.
COMPRESSED-AIR COLD DRYING
The temperature of the compressed air is
reduced to 2 degrees Celsius by a refrigerating plant.
The water which forms is then removed.
Pneumatics Technology
COMPRESSED-AIR DISTRIBUTION
The input of pneumatic energy takes
place through the main line through the use of
pipes.
At the machine itself, distribution is
usually through plastic hoses.
Correct dimensioning and
pipeline network and of the hose
important factor in the provision of
and non-fluctuating supply of
energy.
routing of
lines is an
an efficient
pneumatic
FACTORS
WHICH
DETERMINE
THE
CORRECT DIMENSIONING OF PIPES AND
HOSES ARE:
1.
2.
3.
4.
Flow quantity
Length of the line
Permissible pressure loss
Operating pressure
layout.
RING MAIN
3/2 way
Shut-off Valve
Pressure
Regulator
Filling
Valve
3/2 way
Shut-off Valve
Filter with
Water Trap
Pressure
Gauge
Lubricator
Pneumatics Technology
Dosing
Screw
Pressure
Regulator
Deflector
Tunnel
Filler Plug
Sinter
Filter
Element
Atomizer
Nozzle
Condensate
Drain
Deflector
Plate
10
Compressors
normally
supply
unclean
compressed air to pneumatic systems. This air is fed into
the inlet of the air-service unit and will pass through the
filter with water trap where it is caused to rotate
through the deflector tunnel by a vortex insert (a
whirling mass of air that draws everything near it
towards the center). The centrifugal force flings the
water held by the compressed air to the outside and it
then collects in the base of the water trap.
The filter will separate the solid and liquid
contaminants from the air. Solid contaminants
(dust/dirt) may block the normal operation of a number
of pneumatic components. Liquid contaminants
(mainly water) lead to internal corrosion of pneumatic
components.
Air-service Unit
Filter
Reservoir
Air-service Unit
Mode of Operation
Unclean
Compressed Air
Inlet
Draining
Screw
Deflector
Plate
Sinter
Filter
Pneumatics Technology
Main
Pressure
Pressure
Regulator
Compressed
Air
11
Operating
Pressure
The cleaned compressed air is then
passed through a fine-pored sinter filter to the
filter-units outlet.
When the compressed air enters the
regulator, the cleansed supply air (primary
pressure) will be regulated to the desired
secondary pressure (operating pressure). The
secondary pressure (operating pressure) will
exit the regulator through the outlet port.
Dosing
Screw
Oil-mist
Lubricator
Oil
Reservoir
Pneumatics Technology
12
PRESSURE REGULATOR
The pressure regulator (known also as
pressure reducing valve) is a component having
two ports - an inlet and an outlet port. It
maintains s constant pressure at the outlet port,
which is lower than the pressure at the inlet
port. It reduces the main pressure to a given
(adjustable) operating pressure, and maintains it
at this level even when the loads and mains
pressure fluctuate.
Pressure Regulator
Mode of Operation
Diaphragm
Outlet Port
Inlet Port
Pressure Regulator
Housing
Inlet
Pressure
Port
Gap 1
Gap 2
Outlet
Pressure
Port
Pressure
Gauge
Outlet Port
Inlet Port
Big Spring
Diaphragm
Gap 2
Outlet
Pressure Port
Inlet
Pressure Port
Small Spring
Gap 1
Valve
Housing
Gap 1
Valve
Diaphragm
Pneumatics Technology
Large Spring
Inlet
Pressure
Gap 1
Adjustment Knob
Outlet
Pressure
Valve
Constant
Outlet
Pressure
Narrowing of Gap 1
A further increase of the inlet pressure
or a decrease in the air flow rate will lead to the
same reaction of the parts of the regulator. The
result is the further narrowing of gap 1 which
creates a bigger pressure drop in the regulator.
This is the way a constant outlet pressure is
ensured.
Large
Spring
Inlet
Pressure
Gap 1
Diaphragm
Inlet
Pressure
13
Valve
Outlet
Pressure
Gap 1
Diaphragm
Higher Pressure
at Outlet Port
Valve Pin
Gap 2
Pneumatics Technology
In the same time, the big spring no
longer counterbalances the valve against the
force of the small spring. Consequently, the vale
moves to the position, when the valve disk
closes gap 1 and no further pressure is provided
to the system for the inlet of the regulator.
This state of the regulator will be
maintained, until the high pressure on the outlet
port drops to a level, lower that the presetting of
the regulator. When that happens, the
diaphragm moves back to the point, when gap 2
is closed and the pressure regulator starts to
operate as described in the initial pages.
OIL-FOG LUBRICATOR OR
OIL-MIST LUBRICATOR
The oil-fog lubricator operates according to the
Venturi principle (a constriction in a tube designed to
cause a pressure drop when a liquid or gas flows
through it) by which the vacuum resulting from a
reduction in area, oil is drawn up through a narrow pipe
which reaches into the lubricators oil reservoir. The oil
then dips into the compressed air as it passes through
and forms as a fine fog.
Pressure Regulator
Housing
Typical picture of an Oil-fog Lubricator
Inlet
Pressure
Port
Oil-fog Lubricator
Pressure
Gauge
Outlet
Pressure
Port
Pressure Gauge
14
Pneumatics Technology
15
SUPPLEMENTARY COMPONENTS
FOR THE AIR-SERVICE UNIT
FILLING VALVE
Relief and
Sequence Valve
Additional
Micro-Filter
Oil-Free
Compressed Air
Rapid-Exhaust
Valve
RELIEF VALVES
They are used to relieve the air-service
unit from excessive pressure fluctuations. They
are inserted in the upstream and downstream of
the air-service unit or between the individual
items of equipment.
SEQUENCE VALVES
The sequence valve is usually located on
the supply line of a cylinder or on a branch of a
pneumatic circuit that is isolated from the main
circuit. When the pressure in the main circuit
reaches the set pressure of the sequence valve, it
opens and lets air flow to the cylinder or to the
branch of the circuit.
RAPID-EXHAUST VALVES
They are used to stipulate that cylinder
movements are to take place as quickly as
possible.
Supplementary Components
For the Air-service Unit
Lubricated
Compressed Air
Pneumatics Technology
DRIVE ELEMENTS
3.
SINGLE-ACTING CYLINDERS
The single-acting cylinder converts the
compressed air energy into mechanical energy
in the form of force and linear movement in one
direction only.
16
Bellows-type Cylinders
Note that bellows is a device or piece of
equipment with a compressible chamber
with flexible sides that can be expanded to
draw air in and compressed to force the air
out.
Diaphragm or bellows-type cylinders can
have diameters of up to 710 mm.
They can generate forces of up to 190 kN at
pressures of 7 bars.
Pressure Port
Cylinder Tube
Cylinder Rod
Exhaust Port
Cylinder Cover
Cylinder Bottom
Pressure Port
Exhaust Port
Piston
Rod
Spring
2.
Piston cylinders
Note that a piston is a metal
cylinder that slides up and down
inside a tubular housing, receiving
pressure from or exerting pressure
on a fluid.
Typically, the piston can have
diameters of as much as 100 mm.
The working speed is in the range of
50 to 500 mm/s.
Cylinder forces are about 4 kN.
Short-stroke Cylinders
Note that the length of stroke is the
actual working movement. The
shorter stroke enables the cylinder
to lift heavy loads. They can also be
equipped with an anti-rotation
anchor, external guidance and a
magnetic ring for triggering noncontact signaling elements.
Piston
Area
Base end
Cover
Tube
Annular Area
Head end
Cover
Pneumatics Technology
17
Piston Area
Mode of Operation
Piston Area
Piston
Spring
Cylinder Bottom
Spring
Piston Area
Piston
Spring
Pneumatics Technology
DOUBLE-ACTING CYLINDERS
Cover
Port
Tube
18
Port
Piston cylinders
Stroke lengths are up to 500 mm.
The working speed is in the range of
30 to 2000 mm/s.
Cylinder forces are about 40 kN.
2.
Short-stroke Cylinders
Short-stroke cylinders are used
when short strokes are required
together with high forces.
Piston
Adjustable
Throttle
Rod
Cushion /
Bottom Cap Seal
Plunger
Adjustable
Throttle
Tube
Piston
Area
Piston
Port
Cover
Annular Area
Cross-sectional view of the components construction
Double-Acting Cylinder
Typical picture of Short-stroke Cylinders
Double-Acting Cylinder
with Adjustable Stroke Cushioning
Rod
Pneumatics Technology
19
Mode of Operation
Piston Area
Piston
Piston Area
Annular Area
Piston Area
Piston
Rod-cushioning
Plunger
Forward cushion
Throttle
Cushion Seal
Piston
When the annular area is connected to the
pressure line and in the same time the piston area is
connected to the atmosphere, the piston of the double
acting cylinder moves backwards.
Backward cushion
Throttle
Rod-cushioning
Plunger
Cushion Seal
When the piston reaches the end of the
backward stroke, the rod cushioning plunger will
engage the cushion seal and this will trap the exhausting
air in the piston area. The air is forced through the
backward cushion throttle, decelerating the backward
movement of the piston to a stop. As with the forward
cushion, the purpose is to avoid an uncontrolled shock
at the end of the stroke.
Pneumatics Technology
20
ROTARY ACTUATORS
The rotary actuators transform the
power of compressed air that generates linear
piston movement into a reversible rotary
movement. The piston rod of the actuator is
designed in the form of a toothed rack with two
pistons connected at each end.
The
linear
motion
created
by
introducing an air pressure to the piston/rack
assembly is transmitted through a pinion (small
gear wheel that engages with a larger gear or
with a rack) to create a rotary motion. The
rotation angle could reach and even overcome
360 depending on the cylinder stroke and on
the gear ratio. The chamber between the two
pistons is connected to the atmosphere, to avoid
any trapped air from impeding any motion of
the actuator. Available torque at the shaft is
directly proportional to the difference in air
pressure between the input and output ports.
Rotary actuators are used for turning
details, bending pipes and bars, or for driving
butterfly valves in pneumatic control systems.
Port
Tube
Rotary Actuator
Mode of Operation
Left Piston
Rack
Port
Pinion
Cover
Cover
Piston
Rack
Tube
Piston
Pinion
Cover
Port
Pneumatics Technology
21
Rodless Cylinder
RODLESS CYLINDER
The Rodless cylinders are particularly
suitable for very long piston strokes. A carriage
is magnetically attached to the cylinder which
was made of a non-magnetic material like brass,
by way of the magnetic piston.
Pneumatics Technology
22
DIFFERENTIAL CYLINDERS
BELLOW CYLINDER
TANDEM CYLINDERS
A tandem cylinder is two double acting
cylinders joined together with a common piston
rod, to form a single unit. By simultaneously
pressurizing both cylinder chambers, the output
force is almost double that of a standard
cylinder of the same diameter. It offers a higher
force where installation spaces are restricted.
Bellows-type Cylinder
LOCKING CYLINDERS
A cylinder can be fitted with a locking
head in place of the standard end cover. It will
hold the position of the rod in any position. The
locking action is mechanical ensuring the piston
rod is securely held even under full load.
COMPRESSED-AIR MOTOR
The compressed-air motor converts the
compressed-air energy into rotational movement.
Available torque for the shaft is directly proportional to
the difference in air pressure between the input and
output ports. The output port of a one direction motor is
usually connected to the exhaust and is fitted with a
muffler.
Pneumatics Technology
ACTUATORS, CONTROLLING
ELEMENTS AND SIGNALING
ELEMENTS
23
CLASSIFICATION OF
DIRECTIONAL CONTROL VALVES
type of control
type of the distributing element
number of pneumatic connections or
ports
condition at neutral position whether
normally closed and normally open
valve
REPRESENTATION OF
DIRECTIONAL CONTROL VALVES
Pneumatic elements are shown as
standardized symbols as stipulated in DIN ISO
1219.
Switching
Position
Fittings
Line
Connections
Exhaust
or Vent
Pneumatic
Pressure Source
Internal
Direction
of Flow Connections
Direct
Exhaust
Blocks
DESIGNATION
LETTERS
ISO 5599
INPUTS (Supply)
A, B
4, 2
R, S
5, 3
Z, Y
12, 10
Z, Y
14, 12
Pneumatics Technology
DESIGNATION OF
DIRECTIONAL CONTROL VALVES
2/2 way On/Off DCV
without exhaust
2/2 way Normally Open DCV
3/2 way Normally Closed DCV
2.
MECHANICAL CONTROL
On an automated machine, these valves can
detect moving machine parts to provide
signals for the automatic control of the
working cycle.
3.
4.
ELECTRICAL CONTROL
The electrical operation is effected by a
solenoid and a plunger, and therefore the
units are generally known as solenoid
valves.
Direct acting solenoid valves rely on the
electromagnetic force of the solenoid valve
to move a poppet or spool.
To limit the size of the solenoid, larger
valves have indirect solenoid pilot
operation.
24
Pneumatics Technology
MANUAL CONTROLS
MECHANICAL CONTROLS
PNEUMATIC CONTROLS
ELECTRICAL CONTROLS
NAMING DIRECTIONAL
CONTROL VALVES
25
Pneumatics Technology
2
26
12
10
3 1
Housing
Outlet Port
Distributing
Spool
Port 3
Port 1
Spring
Push-button
Distributing
Spool
Outlet Port
Spring
Pressure
Inlet Port
Air under
Pressure
Exhaust
Port
Exhaust
Port
Pressure
Inlet Port
12
10
1 3
Pneumatics Technology
27
Mode of Operation
3/2 way Normally Closed Directional Control
Valve, Push-button Actuated, Spring Return
Outlet Port
Outlet Port
Spool
Spool
Pressure
Inlet Port
Exhaust
Port
Exhaust
Port
Pressure
Inlet Port
Exhaust
Port
Pressure
Inlet Port
Pneumatics Technology
28
Outlet Port
Spring
Spool
Spool
Pressure
Inlet Port
Air under
Pressure
Exhaust
Port
Spool
Pressure
Inlet Port
Exhaust
Port
Pressure
Inlet Port
Air under
Pressure
Exhaust
Port
Pneumatics Technology
5/2 PNEUMATICALLY OPERATED
DIRECTIONAL CONTROL VALVES
Basically, the 5/2 directional control
valve functions the same as the 4/2 version. The
only difference being that due to its design as a
spool valve, the 5/2 has an additional exhaust
port (5). In practically all applications, it is just
as suitable as the 4/2 version but because of its
outstanding features in terms of size, easy
actuation and air passage being possible in
both directions, the 5/2 is sometimes actually
preferable to the 4/2 version.
The principles of operation of the
pneumatically operated 5/2 directional control
valve is dependent upon the movement of the
spool inside the valve. The component shifts the
connection between two outlet ports with a
pressure inlet port and an exhaust port. By this
means, pneumatic control of the system is
achieved. In such valves, normally outlet ports
are indicated as 2 and 4, pressure port 1, and
exhaust ports 3 and 5.
Control
Input
Housing
Valve
Spool
Exhaust
Port
Outlet Ports
Pressure
Inlet Port
Side Cover
Exhaust
Port 3
Outlet
Port 2
Pressure
Port 1
Outlet
Port 4
Exhaust
Port 5
Control
Input
Exhaust
Port
Side Cover
29
Pneumatics Technology
PNEUMATIC IMPULSE VALVES
30
Mode of Operation
PNEUMATICALLY CONTROLLED
DIRECTIONAL CONTROL VALVES
In general, pneumatically controlled
directional control valves are always used in the
following applications:
1.
2.
3.
Pneumatics Technology
5/2 ELECTRICALLY OPERATED
DIRECTIONAL CONTROL VALVES
Electric
Control
Housing
Outlet
Ports
Spring
Magnet
Slug
Exhaust
Port
Pressure
Inlet Port
Exhaust
Port
Solenoid
Exhaust
Port 5
Pressure
Port 1
Exhaust
Port 3
Typical picture of another version of a 5/2 way
Solenoid-Controlled Impulse Valve
Solenoid
Housing
Outlet
Port 4
Outlet
Port 2
31
Pneumatics Technology
32
Mode of Operation
Pneumatics Technology
DESIGN PRINCIPLES OF
DIRECTIONAL CONTROL VALVES
The following valve features all depend
upon the design principle used for the valve:
service life
size
actuating force
type of actuation
porting or connection type
flow direction
switching travel
switching
sealing-element wear
33
Seat
Elastic seal
2
TYPES OF DIRECTIONAL
CONTROL VALVES
Slide
Valves
Plane Slide
Valves
Rotary
Valves
Poppet
Valves
Spool
Valves
Elastic seal
1
Seat
Metal Seal
Elastic Seal
2
3
POPPET VALVES
A poppet is valve with vertical guide
and that it is raised and lowered by a vertical
guide, for example, the intake and exhaust
valves of the cylinders in an internal-combustion
engine is also called poppet
The flow through a poppet valve is
controlled by a disc or plug lifting at right
angles to a seat, with an elastic seal.
Pneumatics Technology
SLIDE VALVES
3.
ROTARY VALVES
SPOOL VALVES
1
Spool Valve
2.
14
12
3
5
Plane Slide Valve
34
Pneumatics Technology
35
14
12
Pneumatics Technology
36
FREE-OF-OVERLAP FEATURE
The poppet valve below switches due to
the control plunger being forced down against
the force of the spring, and due to the force
acting on the pilot-piston area or the pressure
area.
REVERSE-FLOW FEATURE
2
1 3
Pneumatics Technology
37
AIR SPRINGS
MECHANICAL DETENT
Metal spool valves inherently have very
low levels of sticking friction due to them not
using seals. In order to ensure that the spool
remains in position even when it is fitted
vertically and when vibration and impacts
occur, the valve is provided with a detent
facility.
A spring-loaded ball engages in two
grooves, and the force it exerts maintains the
valves switching position.
14
3
1
Internal Air Spring
12
14
14
12
3
1
External Air Spring
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PILOT CONTROL OF
DIRECTIONAL CONTROL VALVES
Pilot control of directional control
valves becomes necessary when the actuating
force required for the valve becomes excessive.
This applies especially to poppet valves, and in
particular to manually and mechanically
controlled valves. In other words, pilot control is
required when the valves must be frequently
operated by hand or triggered by lightweight
workpieces.
12
38
12
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2
12
12
2
3
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FLOW-CONTROL VALVES
SPEED REGULATION VALVES
SPEED CONTROLLER VALVES
An essential advantage inherent in
pneumatic control engineering is the fact that it
is an uncomplicated and inexpensive matter to
adjust the working speed of cylinders and
rotary actuators, as well as the speed of air
motors. Cylinder piston rod speeds depend
upon a number of factors:
The speed restriction due to throttle
valves and non-return valves with
restriction
Mechanical conditions, load and load
changes
Flow cross-sectional areas of actuators
Diameters of hosing and tubing and the
length involved
Amount of pressure and pressure
changes in the system.
THROTTLE VALVES
Throttle valves are members of the flow
control family. Fitting an adjustable throttle
valve to reduce the cross-sectional area enables
the compressed-air flow rate to be adjusted, and
with it the working speed.
2
Screw-Insert Throttle Valve
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CHECK VALVE OR
NON-RETURN VALVE
A non-return valve allows air to flow in
one direction and seals it off in the the opposite
direction. Non-return valves are incorporated in
speed controllers such as one-way flow-control
valves and in seal fittings.
Non-Return Valve
PILOT-CONTROLLED
NON-RETURN VALVE
The piloted operated check valve (open)
behaves like the conventional check valve when
there is no pressure applied at the pilot-control
port (21). The only difference is that when the
pilot pressure is positive (non-zero), the check
valve is opened and the fluid can flow from
port 2 to port 1.
21
2
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ONE-WAY FLOW-CONTROL VALVE
THROTTLE CHECK VALVE
NON-RETURN VALVE WITH
RESTRICTION
If 4/2 directional control valves are used
as actuators, or when the cylinder and the 5/2
directional control valve acting as the actuator
are too far apart, screw-insert throttle valves
cannot be used for speed adjustments because
the distance involved make precise control
impossible.
Throttle valves cannot be used either
because in such cases, because otherwise the
restriction is effective in both directions.
Therefore, an assembly comprising of a throttle
valve and a non-return valve connected in
parallel is used.
43
Mounting
Screw
Port 1
Housing
Port 2
Spring
Port 2
Port 1
Check Valve
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44
Air under
Pressure
Outlet
Port
Inlet
Port
Inlet
Port
Non-Return
Valve
Outlet
Port
Regulating Screw
NON-ADJUSTABLE
ONE-WAY FLOW-CONTROL VALVE
Another version of the one-way flow-control
valve is the screw-insert version which can be screwed
directly into the cylinder ports. This design shows that
the effective throttling area is not adjustable and is
dependent only on the opposing forces of incoming
pressure and the spring. Throttling is only effective from
port 1 to port 2 and absolutely no air flow in the
opposite direction.
Inlet
Port
Outlet
Port
Effective Throttling Area
By
turning
the
regulating
screw counterclockwise the throttle will open
which means that the effective throttling area
will be different from zero.
Now the compressed air flows under
pressure through the throttle from the inlet
towards the outlet port also known as port 1 to
port 2. The flow rate can be controlled in a
continuous manner by adjusting the effective
area of the throttle. This is achieved by turning
the regulating screw counterclockwise.
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TYPES OF RESTRICTION OR
THROTTLING WITH
THROTTLE-CHECK VALVES
45
INLET-AIR THROTTLING
USING METER-IN CIRCUIT
Due to the fact that the compressed-air
is compressible, uniform cylinder working
movements are impossible to achieve when
inlet-air throttling is employed.
The jerking (strong sudden movements)
cylinder piston movements depend upon the
cylinder diameter and the load fluctuations
which the cylinder is subjected to.
EXHAUST-AIR THROTTLING
USING METER-OUT CIRCUIT
When this method is employed, the piston of
the double-acting cylinder is virtually clamped
between two air cushions. Full pressure is applied at
the inlet-air side and the exhaust air is throttled. This
leads to uniform cylinder movement.
With double acting cylinders, therefore,
exhaust-air throttling is always applied. The smallest
cylinders, that is, the short-stroke cylinders are an
exemption to this rule, because not enough pressure can
build up in the inlet side of such cylinders.
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QUICK EXHAUST VALVE OR
RAPID EXHAUST VALVE
Quick exhaust valves are used if it is
stipulated that the cylinder movements are to
take place as quickly as possible. The quick
exhaust valve is a member of the check valve
family and is always fitted directly to the
appropriate cylinder port.
This component permits a maximum
out-stroking piston speed by exhausting the
cylinder directly at its port with a great flow
capacity, instead of through the tube and valve.
46
Quick-exhaust
valves
are
fitted
whenever it is necessary to bypass line
resistances, or when valves are concerned, the
through-flow resistance.
In combination with a given volume
(provided for instance by an adequately
dimensioned compressed-air reservoir), the
quick-exhaust effect can be utilized for blowingout or rejecting workpieces.
SILENCERS
The sudden venting or exhaust of the cylinder
chambers generates lots of noise especially to largevolume cylinders. As a result of regional noiseemission regulations, therefore, it is imperative that the
quick-exhaust valves are fitted with silencers. The speed
of the exhausted air is reduced sharply in the interior of
the silencer with the result that the decompression noise
is also reduced. Silencers are used to diminish the noise
and the carry over of particles produced by air exhausts
on the various pneumatic components. They are
installed at the exhaust port of most valves.
R
Typical picture of a Silencer
Quick-Exhaust Valve
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A1
SHUTTLE VALVES
OR OR VALVES
E1
E2
Shuttle Valve
OR FUNCTION BLOCKS
E1
A3
A2
A1
E2
E3
E5
E4
E6
A2
A1
E1
E2
E1
E2
E3
E4
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PRESSURE-SHUTTLE VALVES
OR AND VALVES
The pressure-shuttle valve is also used
for logical operations using pneumatic signals.
The valve has two inlets (E1 and E2) and an
outlet (A).
Since a signal shall only be present at
the outlet until a signal is present at both inlets,
this valve is regarded as a Logical-AND-Valve.
The pressure-shuttle valve in itself is not
to be regarded as a safety-function valve, but
only as a logical-function valve in the
appropriated sub-assemblies.
If the two applied signal pressures are
unequal, it is always the lower pressure which
appears at the outlet.
12
E1
E2
Equivalent Circuit with Directional Control Valve
Typical picture of a Pressure Shuttle Valve
A3
A2
E1
E2
E1
E2
E3
E4
E5
E6
A3
A1
E1
E2
E1
E2
E3
E4
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GATE VALVES OR
SHUT OFF VALVES
STOP-CONTROL VALVES
USED IN LOCKING UNITS
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PRESSURE-CONTROL VALVES
PRESSURE-RELIEF VALVE
The members of the family of pressurecontrol valves are designed to control the level
of pressure in the system. Some reduce and
regulate the pressure levels and while others
sense the level of pressure at certain points in
the system to relieve excess pressure, or just to
allow air flow through them or trigger electrical
functions when certain levels of pressure has
been detected.
PRESSURE REGULATOR
The pressure regulator maintains the
pressure constant at its output, even if the
input pressure varies. An adjustment knob will
allow users to modify the output pressure of the
regulator.
Pressure Regulator,
Adjustable,
Relieving type
Pressure Regulator,
Relieving type
Pressure Regulator,
Adjustable,
Non-Relieving type
Pressure Regulator,
Non-Relieving type
Pressure Switch
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SEQUENCE VALVE
PNEUMATIC ACCESSORIES
AIR DRYER
The air dryer is usually installed at the output of
compressors to extract the moisture contained in
compressed air, so that it does not damage pneumatic
components. Air dryers function by refrigeration or
chemical action. In both cases, the moisture transforms
into condensate and is extracted with a separator.
Sequence Valves,
With Pressure Relief
Air Dryers
FILTERS
Filters purify the air by blocking the solid
contaminants. They are available in various filtration
grains and are used in various places in a pneumatic
circuit. Where air moisture condensation may form, a
filter with an automatic drain must be installed. The
condensate accumulates in the filter's bowl up to a
certain level. A floater then activates the opening of the
filter drain and the condensate is expelled. The drain
closes when the bowl is empty.
Sequence Valves,
With Check Valve
AIR-SERVICE UNIT
This component combines filtration,
pressure regulation and lubrication functions.
Filter
Air-service Unit
51
Filter
with Water Trap
Water Trap,
Manual
Filter
with Water Trap,
Automatic
Water Trap,
with Automatic Drain
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LUBRICATOR
SILENCER
Silencer
PRESSURE INDICATOR
Lubricator
COOLER
A cooler is used when you need to
lower the temperature of compressed air. A
cooler is usually located at the output of a
compressor, before the conditioning units.
Typical Picture of a Pressure Indicator
Green
Cooler
Pressure Indicator
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T-CONNECTORS
COUPLER
PNEUMATIC DISTRIBUTORS
Coupler or
Quick Release Coupling
Uncoupled, Line open
Coupler with
Check Valve
Uncoupled, Line open
Typical Picture of a Pneumatic Distributor
Quick Release
Coupling,
Coupled
Quick Release
Coupling, with
Mechanically-opened
Check Valve
PLUGS
Plugs are used to block fluid flow. The
two plugs on the left are used to plug
distributors' ports. The plug on the right is used
to prevent fluid to flow in a pressure line.
Plugs
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SUB-ASSEMBLIES
When pneumatic drive elements are
combined with mechanical devices or with
valves and other elements to form a unit, and
are installed and used in this form, one refers to
such units as sub-assemblies. They are to drawn
inside a square to stipulate that they are subassembly units. Such examples are:
Guide units
Feed units
Force converters
Clamping units
PNEUMATIC TIMERS
P/R
R/P
PNEUMATIC TIMER,
SUB-ASSEMBLY TYPE
PR
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If a continuous signal is applied to pilotcontrol port (Z), air flows into the reservoir
through the throttle point of the non-return
valve with restriction.
Input
Pressure (P)
Input
Pressure (R)
Output
Pressure (A)
Output
Pressure (A)
T
The output pressure is delayed
by the specified timer amount (T).
T
The output pressure is maintained only
within the specified timer amount (T).
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A
Input
Pressure (P)
Output
Pressure (A)
T
The output pressure is delayed
by the specified timer amount (T).
PNEUMATIC-MECHANICAL TIMER
If the accuracy of pneumatic timers is
inadequate because for instance if pressure fluctuations
are present or if very long delay time is required,
pneumatic-mechanical timers are used.
These so-called pre-setting timers feature time
delay settings of 0.3 second to 100 hours with an
accuracy of about 2 %.
Input
Pressure (R)
Output
Pressure (A)
T
The output pressure is maintained only
within the specified timer amount (T).
A
a, X
t
Z
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PNEUMATIC TWO-HAND
CONTROL BLOCK
Stringent safety regulations apply when
controls are concerned in which operators can
reach into devices or installations and in doing
so, run the danger of injury.
As a mandatory safety requirement, two
manually-operated pushbuttons with recessed
knobs must be fitted to the installation in such a
manner that it is impossible for both knobs to
be depressed using only one hand or arm.
E2
E1
57
A
S
E1
E2
E1
E2
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VACUUM ENGINEERING
Vacuum engineering is employed in
applications
where
transportation
and
stopping functions must be performed with
very great care.
With holding forces of up to 350
Newton, flat, slanting or round workpieces with
rough, smooth or uneven surfaces can be safely
transported.
Suction Cup Diameter
In millimeter
10
20
40
60
95
Holding Force
In Newton
3, 6
14, 3
57, 1
128, 5
350
58
MECHANICAL PUMPS
They are used when a large number of
suction cups are to be operated simultaneously,
or a range of applications must be supplied from
a central point.
VACUUM EJECTORS/GENERATORS
On the other hand, Ejectors can be
employed to generate vacuum. They are suited
for direct operation of up to as many as 3
suction cups.
The vacuum generator uses the Venturi
effect to create a vacuum. The air going through
the Venturi is accelerated because of the
decreasing diameter in the Venturi. As the air
flow increases, pressure decreases. The vacuum
cups function with this pressure drop.
Vacuum Generator
Pneumatics Technology
VACUUM / SUCTION CUP
The vacuum/suction cups are the
working elements employed in vacuum
engineering. They are handling devices for
objects presenting a flat surface. They are either
of the Flat-type or the Telescopic-type.
59
80
60
40
20
1
3
PE (Bar)
3
2
1
10
20
30 40 50
% Vacuum
60
70
80
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PNEUMATIC SIGNAL TYPES
AND CONTROL TYPES
In accordance with DIN 19226, controls
are classified according to:
1.
2.
3.
TYPES OF CONTROL
LOGICAL
CONTROL
SEQUENTIAL
CONTROL
Command-Variable
Control
Programmed
Control
Holding-Element
Control
TIME-ORIENTED
SEQUENTIAL
CONTROL
PROCESS-ORIENTED
SEQUENTIAL
CONTROL
Time-Scheduled
Control
Position-Scheduled
Control
60
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POSITION-DEPENDENT
CONTROLS
When an actuator performs a movement
(for instance, the cylinders piston rod moves
out), and a second operation is triggered
depending upon the rods movement (which is
monitored and signaled back), this is referred to
as Position-dependence.
Position switches or Limit switches are
used to register and signal back such
movements. For the most part, 3/2 directional
control valves are used as position switches in
pneumatic engineering. These are mechanicallycontrolled valves with spring return. One
prerequisite for the use of such valves is that
only low actuating forces should be needed.
Plunger
S2
Ball
Representation of Roller with Idle Return
Spring Rod
Pressure Nozzle
No Mechanical Contact
Roller
S1
Pressure
Nozzles
Roller
Mechanical Contact
S1
Roller
with Free Return
Mechanical Contact
When Extending
Mechanical Contact
When Retracting
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REPRESENTATION OF
PNEUMATIC CIRCUIT DIAGRAMS
The arrangement of the graphical
symbols in a circuit diagram should correspond
to the control loop schematic diagram.
DESIGNATION OF PNEUMATIC
ELEMENTS IN CIRCUIT DIAGRAMS
There is no concrete standardization
applicable to pneumatic circuit diagrams.
Among the possible designation systems are:
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SEQUENTIAL REPRESENTATION
OF MOTIONS
As soon as there are more than two
drive elements in a control, it becomes
imperative that the control sequence is
represented of diagrams.
3.
SHORTHAND NOTATION
Z1
Z2
Z1
Z2
Z1
1.
A
B
A
B
CYLINDER 1
CYLINDER 2
Extend
Extend
Retract
Retract
4.
Z2
Z1
Z1
Z2
Z2
POSITION-SEQUENCE DIAGRAM
The functional sequence of one or more
drive elements together with the respective
components can be shown using two
coordinates.
POSITION-SEQUENCE DIAGRAM
Step 1
2
POINTER REPRESENTATION
Z1
Z2
Z1
Cylinder 2 (Z2)
4=1
2
1
2
1
Z2
The POSITION is shown in the ordinate while the
STEP is shown in the abscissa.
5.
A
B
A
B
Z1
Cylinder 1 (Z1)
Z1
Z2
Z1
Z2
Z2
TABULAR REPRESENTATION
STEP
2.
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POSITION-TIME DIAGRAM
POSITION-TIME DIAGRAM
Time(s)
0
1
Cylinder 1 (Z1)
Cylinder 2 (Z2)
2
1
2
1
10 11
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Note:
14
14
12
12
FUNCTION CHART
Signal
Line
Mechanicallycontrolled Signaling
Elements
Actuated
Position
Normal
Position
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GENERATING A FUNCTION CHART
Time(s)
Step
COMPONENTS
Designation
Identification
State S3
Cylinder (A)
2
1
Directional
control valve (V1)
1.3
14
12
S0
S2
6=1
S1
S4
Cylinder (A)
2
1
Directional
control valve (V2)
1.6
14
12
Directional
control valve (S0)
1.1
12
10
Directional
control valve (S1)
1.7
12
10
Directional
control valve (S2)
1.5
12
10
Directional
control valve (S3)
1.2
12
10
Directional
control valve (S4)
1.4
12
10
S3
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SIGNAL SWITCH-OFF SOLUTIONS
Annular
Area
2.
3.
67
POSITION-SEQUENCE DIAGRAM
Step
1
Cylinder 1
S0
S1
DCV 1
14
12
S3
Cylinder 2
DCV 2
2
1
S2
14
12
5=1