DIPLOMA IN MECHANICAL ENGINEERING (DKM4/DTP4/DEM4/DMB4)

PRACTICAL TASK 1: PNEUMATIC CIRCUIT

COURSE CODE : DJJ5123

COURSE : PNEUMATIC AND HYDRAULIC

NAME : REGISTRATION NO:

DATE : SUBMISSION DATE :

CLASS :

LECTURER :

PREPARED BY: CHECKED /

APPROVED BY:

(PUAN ZUHAILA MOHAMMAD )

PLO 4 PLO 8 Generic Skill:

CLO 2 Practical CLO 3 Professionalism,
Task1
LD 2 LD 8 Ethics and
Moral

A A

B B

C C

D D

E E

TOTAL MARKS TOTAL MARKS

/25 /25
(100%) (100%)
 DJJ5123 PNEUMATIC AND HIDRAULIC
PRACTICAL TASK 1
Practical Skills – LD2
PLO4 apply appropriate techniques, resources, and engineering tools to well-defined mechanical engineering
activities, with an awareness of the limitations
Skills / Excellent Very Good Good Fair Unsatisfactory
SCORE
Aspects 5 4 3 2 1
Ability to
setup
compress Follows the Followed the Not followed
Followed the Fairly followed the
air standard standard the standard
standard standard
preparation procedure procedure but procedure at
procedure. procedure.
with a safety completely. with a mistakes. all.
precaution
awareness
Not gathered
Moderately all needed
Gathered all circuit Gathered all
gathered all circuit Not gathered all circuit and
and components circuit,
Ability to and components needed circuit components
and completely components,
complete but take a few and components and was
ready to start the and ready to
the task times to start the to start the task. unable to
task. start the task.
task. (2/5 circuits) start the
(5/5 circuits) (4/5 circuits)
(3/5 circuits) task.
(1/5 circuit)
Moderately know
Completely know Know to identify Know the every Completely
Demonstrat to identify the
to identify and and explain the pneumatic not know to
e the function of the
explain the function of the components but identify and
knowledge every pneumatic
function of the every pneumatic circuit flow did explain the
of the components and
every pneumatic components and not know to function of
pneumatic circuit flow with
components and circuit flow with explain the pneumatic
circuit moderate
circuit flow. guidance. function. component
guidance.
Unable to
Moderately complete an
Able to Unable to
Able to complete complete an assembly
complete an complete an
an assembly using assembly using Using
assembly using assembly Using
Lecturer Indirect Control Indirect Control Indirect
Indirect Control Indirect Control
guidance. Using Pilot- Using Pilot- Control
Using Pilot- Using Pilot-
Operated Valve Operated Valve Using Pilot-
Operated Valve Operated Valve
task without task with a Operated
task with a little task without
guidance. moderate Valve task
guidance. major guidance.
guidance. with
guidance.
Time
management. Well time Well time Moderately time Unable to
(based on Unable to
management to management to management but complete the
successfully complete the
task given) complete the task complete the not get on time task with
task at all.
successfully. task. finished. adequate time.

𝑆𝐶𝑂𝑅𝐸
𝑥 100%
25
 COURSE LEARNING OUTCOMES (CLO):

Upon completion of this course, students will be able to:

CLO2. Construct accurately pneumatic, electro-pneumatic, electro-hydraulic and

hydraulic circuit according to assigned task. (P4, PLO4)

CLO3. Demonstrate understanding of engineering norm and practices in pneumatics

and Hydraulics during practical work sessions. (A3, PLO8)

SAFETY MEASURES WHEN USING PNEUMATIC CONTROL SYSTEMS

 a. Compressed air can cause serious damage to the human body if they enter the body
through ducts like the oral cavity or ears.
b. Never spray compressed air onto anyone.
c. Under high temperature, compressed air can pass through human skin.
d. Compressed air released from the exhaust contains particles and oil droplets, which can
cause damage to eyes.
e. Even though the pressure of compressed air in pipes and reservoirs is relatively low,
when the container loses its entirety, fierce explosions may still occur.
f. Before switching on a compressed air supply unit, one should thoroughly inspect the
whole circuit to see if there are any loose parts, abnormal pressure or damaged pipes.
g. A loose pipe may shake violently due to the high pressure built up inside it. Therefore,
each time before the system pressure is increased; thorough inspection of the entire
circuit is required to prevent accidents.
h. As the force produced by pneumatic cylinders is relatively large, and the action is usually
very fast, you may suffer serious injuries if you get hit by a cylinder.
i. Switches should be installed on the compressed air supply unit to allow easy and speedy
control of air flow.
j. In case of a leakage, the compressed air supply unit should be turned off immediately.
k. The compressed air supply unit must be turned off before changes can be made to the
system.
l. Stay clear of the moving parts of the system. Never try to move the driving parts in the
mechanical operation valve with your hand.

EQUIPMENT REQUIRED
FESTO; Pneumatic Workbench

PROCEDURE
 PROCEDURE SUMMARY
In the first part of the exercise, you will verify the status of the trainer by executing the
"trainer status verification procedure".

In the second part of the exercise, you will set up and operate a pneumatic circuit using
the Conditioning Unit, a directional control valve and a cylinder.

Trainer Status Verification Procedure

Each procedure in this manual that requires the use of the Pneumatics Trainer includes
the statement: "Verify the status or the trainer according to the procedure given in
Exercise 1-2". This status verification procedure consists of the following steps:

 Install the work surface on a work table or on a support bench, if any.

 Make sure the work surface is secured to the work table or support bench to ensure
that it will not move or fall down.
 If you use a support bench, make sure the four caster brakes are locked.
 On the Conditioning Unit, close the main shutoff valve by pushing down on the
control button.
 Pull up the regulator adjusting knob to unlock the regulator and turn it completely
counterclockwise.
 Close the four branch shutoff valves of the manifold (collar in the lower position).
Figure 3 shows the Conditioning Unit with shutoff valves.

Figure 1: Conditioning Unit with Branch Shutoff Valves.

Fundamental Pneumatic Circuit

 1. Locate the following components:

 Conditioning Unit;
 Directional control valve, 3-way, 2-position, pushbutton-operated;
Note: A directional control valve is a device used to open and close flow paths in a
pneumatic circuit.

 Cylinder, 2.7-cm (or 1 1/16-in) bore, 10-cm (or 4-in) stroke, single acting, and spring
return.
Note: A cylinder is an actuator that converts fluid energy into mechanical energy. Single-
acting cylinders generate force in a single direction.
Figure 2: Schematic Diagram Of A Pneumatics Circuit.

2. Mount the components on the work surface and connect the circuit shown in Figure 4
Refer to the connection diagram shown in Figure 1-21 to make your connections.
Connect the Conditioning Unit to the NC (normally non-passing) port of the directional
control valve.

Figure 3: Connection Diagram of a Pneumatic Circuit.

3. On the Conditioning Unit, open the main shutoff valve and the branch shutoff valve at
the manifold. Screw a tip (bullet) to the rod of the cylinder.
4. Pull up regulator adjusting knob to unlock the regulator and turn it clockwise to set the
pressure at 200 kpa (or 30 psi0 on the regulated Pressure Gauge.

Note: Each time you set the pressure, it is recommended to close and reopen the main shutoff
valve to overcome friction. Readjust the pressure if necessary.

TASK: APPLICATIONS IN PNEUMATIC SYSTEM

1.1 OBJECTIVE
i. Using Direct and Indirect Control Using Pilot-Operated Valve
ii. Students will be able to control of double-acting cylinder, and knowing various
types of speed regulation of the piston rod movement of double-acting cylinder.

1.2 THEORY
Direct control
The simplest level of control for the single or double-acting cylinder involves direct control
signals. Using this type of control, the cylinder is actuated directly via a manually or
mechanically actuated valve, without any intermediate switching of additional directional
control valves. If the port sizes of the valve are too large, the operating forces required
may be too great for direct manual operation.

Indirect Control Using Pilot-Operated Valves

To introduce the operation of pilot-operated directional control valves. To learn about
construction and classification. To show the advantages of indirect control in demo
circuits using a long line device, cylinders and a 4-way, 5-port, 2-position pilot-operated
directional control valve.
Pneumatics system performs a variety of tasks, ranging from the very simple to the
very complex. Controlling cylinders is one of the most important aspects of pneumatics.
For example, two cylinders may be required to operate at the same speed, or a cylinder
may need to extend rapidly under no load conditions.
1.3 PNEUMATICS PROBLEMS

A. Direct control of a double-acting cylinder with push-button.

Aim:
This exercise provides direct control of double-acting cylinders with manually
operated 5/2 directional control valves. In addition, the effect of adjustable spring
cushioning in double- acting cylinders can be observed.

Task:
 The piston rod of a double-working cylinder (Z1) should extend after actuating a
button.
 After releasing the button (S1), the piston of the cylinder should retract
automatically to its back position. Refer Figure 1.3 (a).

List of equipment’s:

Description:
i. (01) Air service unit (filter with water separator, pressure regulator and
pressure gauge) with a 3/2 directional control ball valve
ii. (02) Distributor, 6-fold
iii. (04) Double-acting cylinder with adjustable spring cushioning
iv. (08) 5/2 directional control valve with push-button Accessories

Figure 1.3 (a): Direct control of a double-acting cylinder

Circuit Problem:
Using the given components and layout, design a schematic circuit which will
operate one spring return cylinder from any one of three identical valves.

Design and draw schematic diagram. Approved: _______

Connect components to match schematic diagram. Approved: _______

Operate and explain circuit to instructor. Approved: _______

Conclusion:
 The double-acting cylinder can be directly controlled by a ________________________

 In the basic setting (spring position) of a directional valve, port 1 supplied with compressed
air, port 2 is always and port 4 always .
 1.3 PNEUMATICS PROBLEMS (continues)

B. Application

Parts are accumulating on a conveyor belt and waiting to be released and transferred to the
next phase of assembly. Technicians at multiple stations need to control the gate release
mechanism to have parts sent to their assembly station.

Objective:

To be able to design and assemble an “OR” logic circuit.

Circuit Problem:

Using the given components and layout, design a schematic circuit which will operate one
spring return cylinder from any one of three identical valves.

Design and draw schematic diagram. Approved: _______

Connect components to match schematic diagram. Approved: _______

Operate and explain circuit to instructor. Approved: _______

Layout of Components Needed:

Part Component Description Qty

# 1 2-position, spring offset, 3-way valve 3
2 shuttle valve 2
3 push button actuator 3
4 Single acting, spring return cylinder 1

Figure: 1.3 (b)

C. Pressure-dependent control of a double acting cylinder
Aim:
In this exercise, the various types of speed regulation (throttling) of the piston rod
Movements of double-acting cylinders with one-way flow control valves are looked at and
the effects are observed.

Task:
- The cylinder is controlled with a manually operated button (actuator S1). After
releasing the button (S1), the piston of the cylinder should retract automatically to its
back position. Refer Figure 1.3(c)

List of equipment:
Description:
- (04) Double-acting cylinder with adjustable spring cushioning
- (08) 5/2 directional control valve with push-button Accessories
- (15) Flow control valves with non-return, adjustable

Figure 1.3(c): Speed regulation of a double-acting cylinder

Design and draw schematic diagram. Approved: _______

Connect components to match schematic diagram. Approved: _______

Operate and explain circuit to instructor. Approved: _______

Conclusion

Referring to Figure 1.3(c), which circuit demonstrates the following?

a. In Circuit ( ): The speed of the cylinder piston is restricted when
extending.
b. In Circuit ( ): The speed of the cylinder piston is restricted when
retracting.
c. In Circuit ( ): Both speed of the cylinder piston are restricted.
 D. Displacement dependent control of a double-acting cylinder
Aim:
The displacement-dependent control of a double-acting cylinder by using limit
switches in demonstrated in this exercise.
Upon the completion of this task, the student will be
• Familiar with indirect actuation of a double acting cylinder by using a double pilot valve.
• Familiar with using different types of directional control valves

Task description:
Using a diverting device, parts are to be moved from one conveyor track onto the other in a
linear sequence as illustrated in Fig. 1.3(d)(i). By operating a selector valve the oscillating
piston rod of a cylinder pushes the turntable via a pawl in stepped sequence. The parts are
diverted and transported onwards in the opposite direction. By returning the selector valve
back to the normal position the drive unit is switched off.

Figure 1.3 (d)(i): Positional sketch

 Figure 1.3 (d) (ii): Displacement dependent control of a double-acting cylinder

Conclusion:

- Design the functional diagram (stroke-time diagram) for the cylinder and
the 5/2 directional control valve.

- What are used for a displacement dependent control of a double-acting cylinder?

Design and draw schematic diagram. Approved: _______

Connect components to match schematic diagram. Approved: _______

Operate and explain circuit to instructor. Approved: _______

E. Pressure-dependent control of a double acting cylinder

Aim:
By using a 3/2 directional control valve with adjustable minimum pressure of response, a
pressure dependent control (and in addition displacement dependent) control of a double
acting cylinder is put into effect.
Upon the completion of this task, the student will be
• Familiar with indirect actuation of a double acting cylinder with a double pilot valve.
• Able to use and adjust the pressure sequence valve.

Taskdescription:
A plastic component is embossed using a die driven by a double-acting cylinder. The
die is to advance and emboss the plastic when a push button is operated. The return of
the die is to be effected when a preset pressure is reached. The embossing pressure is
to be adjustable.

Figure 1.3(e): Positional sketch

Task requirements:
1. Draw pneumatic circuit diagram
2. Simulate the circuit using Automation studio software.
3. Assemble the circuit practically and check its operation

List of equipment:
Description:
- (21) Pressure gauge
- (22) 3/2 directional control valve, with adjustable operating pressure
- (13) 3/2 directional control valves, with roller
- (04) Double-acting cylinder with adjustable spring cushioning
- (11) 5/2 directional control valve, impulse valve
- (15) Flow control valves with non-return, adjustable
- (06) 3/2 directional control valve, with manually operated push-button
- (13) 3/2 way roller valve for automatic return of the cylinder.
 Figure 1.3(e) (i): Pressure dependent control of a double-acting cylinder

Conclusion:

- Mention the conditions to extend the piston of the cylinder.

- Mention the conditions to retract the piston of the cylinder.

 Prepared by: Zuhaila Mohammad

- Design the functional diagram (stroke-time diagram) for the cylinder and the
5/2 directional control valve.

Design and draw schematic diagram. Approved: _______

Connect components to match schematic diagram. Approved: _______

Operate and explain circuit to instructor. Approved: _______

References:
1. https://www.iei.liu.se/flumes/tmms03/filarkiv/lab/1.451122/Lab2_tmms03_PneumaticControlSystems.pdf
2. https://elearning.ju.edu.jo/file.php/14990/Exp._2_Pneumatic_Control_of_a_Double-
acting_Cylinder_2017.pdf
3. Festo Didactics
Prepared by: Zuhaila Mohammad