DJJ 5123:

HYDRAULICS & PNEUMATICS

Topic 3.0 PNEUMATICS
CIRCUIT DESIGN

1
Introduction

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Introduction

3
Introduction

4
Introduction

5
Introduction

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Introduction

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Introduction

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Introduction

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Introduction

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Introduction

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Introduction
 This module shows the methods  A message to pneumatic
of application of pneumatic circuit designers:
valves and components for  Use proven and reliable design
control and automation. techniques
 Produce circuits and
 The methods of pure pneumatic
documentation that are clear to
sequential control are confined read
to simple examples.  Design for safety

 The majority of modern systems  Do not try to be too clever, the

are controlled electronically and circuit will be difficult for others

is the subject of electro- to read and maintain
pneumatic modules.

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

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Symbols and Standards in Pneumatics

27
3.1 Distinguish movement of the cylinder.
3.1.1 Construct the pneumatic circuit diagram for one cylinder based on:
i. Direct method
ii. Indirect method
3.2 Determine sequence control for numerous cylinder

3.2 .1 Construct the pneumatic circuit diagram for numerous cylinders

based on:

a. Sequence Circuit
b. Cascade method

28
Construct the pneumatic circuit
diagram for one cylinder based
on:

Direct method Indirect method

29
Direct method

• Control types Directly actuated

valves

• Directly actuated valve

30
• For a valve to switch, there must • With directly actuated valves, the
always be a movement within the movement of the valve piston or the
valve. In the simplest cases only a seal can be triggered directly by the

seal is moved, but frequently it is a actuating element (solenoid coil, lever,

valve piston which may have several pedal switch, etc.). This means the

seals. Through the movement of the switching function of the valve is

piston or the seal, the air is directed independent of the operating

from one channel to another, or pressure, and is also suitable for

blocked or enabled. vacuum applications. However, the

force required for moving the valve
the actual valve.
piston increases proportionally to the
size of the valve. On solenoid actuated
valves, the solenoid coil is frequently
larger than the actual valve.

31
Indirect method
Control types indirectly
actuated valves

Indirectly actuated valve

32
• Indirectly actuated valves are also • The major advantage of this type of

designated as pilot actuated valves. actuation is that a low force is

The task of the actuating element sufficient to switch even large valves.

(solenoid coil, lever, pedal switch, On a solenoid valve, this means that

etc.) is only to open or close a small a small coil with low power

pilot bore. The actual movement of consumption is able to switch a large

the valve piston is generated by the valve.

medium - in this case air. However, this only works if pressure

is actually applied.

33
 Circuit layout
 The standard for circuit
diagrams is ISO 1219-2.
 A4 format or A3 folded to A4
height for inclusion in a manual
with other A4 documentation.
 To be on several sheets if
necessary with line
identification code.
 Minimum crossing lines.
 Limit valves position of
operation by actuators shown
by a marker with reference
code to symbol.
⚫ Circuits should be drawn
with all actuators at the top
of the page in order of
sequential operation.
⚫ Other components to be
drawn in sequential order
from the bottom up and
from left to right.
⚫ Circuit should show the
system with pressure applied
and ready to start.
34
 Component identification
 The ISO suggested component  Note: the a0 valve symbol is
numbering system is suited for large drawn in the operated position
circuits and those drawn on several because the actuator A is
pages. instroked.
 For this presentation a simple code a0 a1

A
is used.

 For cylinders: A,B,C etc.

 For associated feedback valves: 2 2

12 10 12 10
alpha-numeric code ‘a0’ for proof of
a0 3 1 a1 3 1
instroke, ‘a1’ for proof of outstroke.

 For cylinder B: b0 and b1.

35
Example circuit
a0 a1 b0 b1 c0 c1
A B C

Sequence
Run/End
A+
B+
B-
C+
C-
A-
Repeat
Run/End

a0 a1 b1 b0 c1 c0

10 bar max 6 bar

To all inlet ports marked
36
Actuator control 2/2 valve

37
 2/2 Valve actuator control
 A pair of the most basic of all valve
types the 2/2 can be used to control
a single acting cylinder.

 The normally closed position of the

valve is produced by the spring. 12
2
10 12
1
10

 The operated position is produced by 1 2

OUT IN
the push button.

 One valve admits air the other valve

exhausts it.

38
 2/2 Valve actuator control
 The button marked OUT is pushed to
operate the valve.

 Air is connected to the cylinder and it

outstrokes.
2 1
12 10 12 10
 Air cannot escape to atmosphere
1 2
through the valve marked IN as this is OUT IN

closed.

 The air at atmospheric pressure in the

front of the cylinder vents through the
breather port. 39
 2/2 Valve actuator control
 The push button of the valve marked
OUT is released and it returns to a
normal closed position.

 Air is now trapped in the system and

provided there are no leaks and the 12
2
10 12
1
10

piston rod will stay in the outstroked 1 2

OUT IN
position.

 If the load increases beyond the force

exerted by the air the piston rod will
start to move in.
40
 2/2 Valve actuator control
 The button marked IN is pushed to
operate the valve.

 Air escapes and the piston rod

moves to the instroked position.
2 1
 The push button must be held 12 10 12 10

operated until the piston rod is fully 1 2

OUT IN
in.

 Atmospheric air will be drawn in to

the front of the cylinder through
the vent port.
41
 2/2 Valve actuator control
 If the button marked IN is
released the piston rod will
remain in the instroked
position.
2 1
12 10 12 10

1 2
 Any leaks in the installation OUT IN
can cause the piston rod to
creep.

42
 2/2 Valve actuator control
 To control the speed of the piston
rod, flow restrictors are placed in
the pipes close to each of the
valves.

2 1
12 10 12 10

 Adjustment of the restrictors will 1 2

OUT IN
slow down the flow rate thereby
giving independent outstroke and
instroke speed control

43
 2/2 Valve actuator control
 By repeated operation of
either button during
movement, the piston rod
can be moved in small steps
for approximate positioning.
2 1
12 10 12 10

1 2
OUT IN
 This will only be successful
under slow speeds.

44
 2/2 Valve actuator control
 With any compressed air system that
intentionally traps air, the potential
hazard of this must be recognised.

 Unintended release or application of 2 1

12 10 12 10
pressure can give rise to unexpected
1 2
movement of the piston rod. OUT IN

 A pressure indicator or gauge must be

fitted to warn of the presence of
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pressure.
Actuator control 3/2 valve

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 3/2 valve actuator control
 A 3 port valve provides the inlet and exhaust path
and is the normal choice for the control of a single
acting cylinder.

 In the normal position produced by the spring, the

valve is closed. 2
12 10

 In the operated position produced by the push 3 1

button the valve is open.

 The push button must be held down for as long as

the cylinder is outstroked.

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 3/2 valve actuator control
 To generally slow the cylinder speed an
adjustable bi-directional flow regulator or
fixed restrictor can be used.

 The flow regulator setting will be a

2
compromise as the ideal outstroke speed 12 10

may not produce the desired results for 3 1

the instroke speed.

48
 3/2 valve actuator control
 To control the outstroke speed of a single
acting cylinder without controlling the
instroke speed, a uni-directional flow
regulator is used.

 The flow into the cylinder closes the non

return valve and can only pass through the
adjustable restrictor. 12
2
10

 By adjusting the restrictor the outstroke 3 1

speed of the cylinder can be set.

49
 3/2 valve actuator control
 For independent speed control in each direction

two flow regulators are required.

 Installed in opposite directions to each other.

 Upper regulator controls the outstroke speed. 2

12 10

 Lower regulator controls the instroking speed. 3 1

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Actuator control 5/2 valve

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 - +
5/2 Valve actuator control
 For a double acting cylinder the power and
exhaust paths are switched simultaneously.
4 2
14 12

 When the button is pushed, the supply at port 1 5 1 3

is connected to port 4 and the outlet port 2

- +
connected to exhaust port 3. The cylinder
moves plus.

4 2
 When the button is released port 1 is connected 14 12

to port 2 and port 4 connected to port 5. The 5 1 3

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cylinder moves minus.
 - +
5/2 Valve actuator control
 Independent speed control of the plus
and minus movements:
4 2
14 12

5 1 3
 In most applications speed is controlled
by restricting air out of a cylinder. - +

 Full power is developed to drive the

piston with speed controlled by 4 2
14 12
restricting the back pressure.
5 1 3
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 5/2 Valve actuator control
 Valves with a spring return are mono-stable and
need the operator to be held all the time that the - +
cylinder is required in the plus position.

 Bi-stable valves will stay in the position they were

4 2
last set. 14
12
5 1 3

 The lever valve, example illustrated, indicates a

detent mechanism. The lever need not be held
once the new position has been established.
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 Manual control
- +
 Remote manual control of a double

acting cylinder:

4 2
14 12

 Valve marked + will cause the cylinder 5 1 3

to outstroke or move plus.

2 2
12 10 12 10

 Valve marked - will cause the cylinder + 3 1 - 3 1

to instroke or move minus.

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 Manual control
 The 5/2 double pilot valve is bi-stable therefore the push button valves
only need to be pulsed.

- + - +

4 2 4 2
14 12 14 12

5 1 3 5 1 3

2 2 2 2
12 10 12 10 12 10 12 10

3 1 3 1 + 3 1 3 1
+ - - 56
 Manual control
 The 5/2 double pilot valve is bi-stable therefore the push button
valves only need to be pulsed.

- + - +

4 2 4 2
14 12 14 12

5 1 3 5 1 3

2 2 2 2
12 10 12 10 12 10 12 10

+ 3 1 - 3 1 + 3 1 - 3 1
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 Semi-automatic control
- + a1
 Manual remote start of a double A
acting cylinder with automatic return:

4 2
 Cylinder identified as “A”. 14 12

5 1 3

 Trip valve operated at the

2 2
12 12
completion of the plus stroke 10 10

identified as “a1”. 3 1 3 1
+ a1
-

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 Fully-automatic control
- +
 Continuous automatic cycling from a0 a1

A
roller operated trip valves:

 Manual Run and End of the

automatic cycling. 4 2
14 12
 Cylinder will come to rest in the
5 1 3
instroked position regardless of 2
10
when the valve is put to End. 12
Run/End 3 1
2 2
 Tags for the roller feedback valves 12 10 12 10

a0 and a1 show their relative

a0 3 1 a1 3 1

positions.
59
Sequential control

60
 Circuit building blocks
a0 a1 b0 b1
A B

Run/End

 These circuits can be considered as building blocks for larger sequential

circuits consisting of two or more cylinders.

 Each actuator will have a power valve and two associated feedback valves.
The first actuator to move also has
a Run/End valve. 61
 Repeat pattern sequence
 A repeat pattern sequence is
one where the order of the
movements in the first half of
the sequence is repeated in
the second half.
 Each actuator may have one
Out and In stroke only in the
sequence.
 There may be any number of
actuators in the sequence.
 The signal starting the first
movement must pass through
the Run/End valve.
 Needs only the basic building
blocks to solve.
 Examples of repeat pattern
sequences:
 A+ B+ C+ D+ A- B- C- D-
 A- B+ C- A+ B- C+
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 C+ A+ B- C- A- B+
 Repeat pattern sequence
a0 a1 b0 b1
A B

Run/End

b0 b1 a1 a0

 The two cylinders A and B are to perform a simple repeat pattern

sequence as follows: A+ B+ A- B-

 Apply the rule “The signal given by the completion of each movement
will initiate the next movement”.

 In this way the roller valves can be identified and labelled. 63

 Repeat pattern sequence
a0 a1 b0 b1 c0 c1
A B C

Run/End

c0 c1 a1 a0 b1 b0

 For three cylinders A, B and C also to perform a simple repeat pattern

sequence as follows: A+ B+ C+ A- B- C-

 Apply the rule “The signal given by the completion of each movement
will initiate the next movement”.
64
 Non-repeat pattern sequence
a0 a1 b0 b1
A B

Run/End

a0 b0 a1 b1

 If the rule applied to a repeat pattern sequence is applied to any other

sequence there will be opposed signals on one or more of the 5/2
valves preventing operation.

 This circuit demonstrates the problem.

 The sequence is A+ B+ B- A- 65
 Opposed signals
a0 a1 b0 b1
A B

Run/End

a0 b0 a1 b1

 When the valve is set to Run, cylinder A will not move because the 5/2
valve has an opposed signal, it is still being signalled to hold position
by the feedback valve b0.

 If A was able to move + a similar problem will occur for the 5/2 valve
of B once it was +. The sequence is A+ B+ B- A-
66
 Mechanical solution
a0 a1 b0 b1
A B

Run/End

a0 b0 a1 b1

 The problem was caused by valves b0 and a1 being operated at the

time the new opposing instruction is given.

 If these two valves were “one way trip” types and over tripped at the
last movement of stroke, only a pulse would
be obtained instead of a continuous signal. 67
3/2 roller lever valve

Without idle return With idle return (one way trip)

68
3/2 roller lever valve

69
3/2 roller lever valve

70
 Sequence solution methods
 The main solutions to solving
sequences are:
 Cascade (pneumatic)
 Shift register (pneumatic)
 Electro-pneumatic
 PLC (Programmable
controller)
 Cascade circuits provide a
standard method of solving any
sequence. It uses a minimum of
additional logic hardware (one
logic valve per group of
sequential steps).
 Shift register circuits are similar
to cascade but use one logic
valve for every step.
 Electro-pneumatic circuits use
logic solenoid valves and electro-
mechanical relays.
 PLC: the standard solution for
medium to complex sequential
systems (except where
electrical equipment cannot be
71
used).
 Cascade two group
 The A+ B+ B- A- circuit is solved by  Because only one group output
the two group cascade method. is available at a time it is not

 The sequence is divided at the point possible to have opposed signals.

where B immediately returns.  A standard 5/2 double pressure
 The two parts are allocated groups l operated valve is the cascade
and ll. Gp l A+ B+ / Gp ll B- A- valve.

 Two signal supplies are provided Group l Group ll

from a 5/2 valve, one is available 4 2
14 12
only in group l, the other is available
Select l 5 1 3 Select ll
only in group ll.
72
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

73
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

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Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

75
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

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Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

77
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

78
 Cascade building blocks
 A two group building block consists
of a lever valve to run and end the Gp l
sequence plus the 5/2 double pilot
Gp ll
operated cascade valve. 4 2
14 12

 For a two group system consisting Run/End

5 1 3 Sel ll
2
of any number of cylinders this 10
12
building block and the cylinder 3 1
Sel l
building blocks are all that is
required to solve the sequence.

79
 Cascade rules
 Establish the correct sequence
• Divide the sequence in to groups.
• Always start a sequence with the
Run/End valve selecting group l
e.g.
R/E | A+ B+ | B- C+ | C- A-
 Select the cylinder building blocks.
 Select the cascade building block.
 Interconnect the blocks as follows:
 The first function in each group
is signalled directly by that
group supply.
 The last trip valve operated in
each group is supplied with main
supply air and selects the next
group.
 The remaining trip valves are
supplied with air from their
respective groups and initiate
the next function.
 The “run/end” valve will control
the signal from the last trip
valve to be operated.
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Home Work:

 Question 1:

A+ B+ C+ A- B- C-

 Question 2:

A+ B+ C+ C- B- A-

 Question 3:

A+ A- B+ C+ C- B-

81
Class Work: ➢ Question: A+ B+ B- C+ C- A-

82
 Logic functions &
Feedback methods

83
Logic NOT
 A logic NOT applies to the state of the Z
output when the operating signal is present 2
10 12
(the output is simply an inversion of the X
1 3
operating signal).

 The valve shown is a normally open type

(inlet port numbered 1). Z

 When the signal X is present there is NOT 10

2
12
X
output Z. 1 3

 When X is removed output Z is given.

84
Logic MEMORY
 A logic MEMORY allows the output signal
state (ON or OFF) to be maintained after
the input signal has been removed. Z
X
 Any bi-stable valve is a logic MEMORY.
12 10
3 1
 With this lever detented valve, once the Y

lever has been moved X direction or Y

direction it can be released and will stay in
that position.

85
Logic MEMORY
 A bi-stable double pilot valve Z

can be set or reset simply by a 12 10

3 1
pulse (push and release) on

buttons X or Y. 2
12 10
Y
3 1
2
12 10
X
3 1

86
Logic MEMORY (latch)
 A popular memory circuit is the latch.
Z
 Will not re-make after pneumatic power 1 3
Y
failure. 12
2
10

12
 A pulse on X operates the pilot / spring 10

3 1
valve to give output Z.

 A feedback from Z runs through the 12

2
10
X
normally open valve Y to latch the 3 1

operation of Z when X is released.

 A pulse on Y breaks the latch and Z is

exhausted.
87
 Logic MEMORY (latch)
Z Z
1 3 1 3
Y Y
12 10 12 10
2 2
12 10 12 10

3 1 3 1

2 2
12 10 12 10
X X
3 1 3 1

88
OR, AND, NOT z 2
OR 12 10

 A single 3/2 pilot operated spring 3 1

return valve can be use for any x y

z 2
of these logic functions: AND 12 10

3 1
 x OR y gives output z x y

z 2
NOT
 x AND y gives output z. 12 10

3 1

 x gives NOT z x

89
Single pulse maker
 Converts a prolonged signal x into z

2
a single pulse z. 12 10

3 1
 Signal x must be removed to

allow the valve to reset then x

x
can be applied again.

 The duration of the pulse can be

adjusted with the flow regulator.

90
 Time delay
 A signal is restricted to slow the rate
of pressure build up on a pressure Output

switch (3/2 differential pressure

2
operated valve). 12 10

3 1
 When the pressure switch operates a
strong un-restricted output is given.
Signal
 A reservoir provides capacitance to in

allow less fine and sensitive settings

on the flow regulator making it easy
to adjust.
91
Time delay
- +
 Manual remote start of a a1

A
double acting cylinder with a
time delay in the outstroked
position before automatic 14
4 2
12

return: 5 1 3

2
12 10

3 1
2 2
12 10 12 10

3 1 a1 3 1

92
Time delay
 Problem:

93
Time delay
 Solution:

94
EXERSICE: PRODUCT SEPARATION

95
96
Solution 1: PRODUCT SEPARATION
Direct circuit

97
Solution 1: PRODUCT SEPARATION
Indirect circuit

98
99