Introduction to Pneumatics

The term PNEUMA is derived from the ancient Greek, and meant breadth or wind. PNEUMATIC is the study of air movement and air phenomena. Although the fundamentals of pneumatics rank amongst the earliest perceptions of mankind, it was not until the last century that the behavior and the fundamentals were researched systematically. Some earlier applications and areas of use of pneumatics in the industry were; railways, mining and construction. Real practical industrial applications of pneumatics dates back only to about 1950s.

Properties of Air

78% 21% 1%

Nitrogen Oxygen Other Gas (CO2, H, Ne, Krypton, Xenon, Water, etc.)

Air is compressible. Air is expandable. Air when compressed produces a maximum temperature of 200 to 300C. Air contains 40PPM of solid particles and increases to 9 times when compressed.

What is Pressure?
PRESSURE is defined as a force or thrust acting on the surface of the body in a uniform manner and at a right angle to the surface.

Force Exerted by Gases:

While liquids conform to the shape of the vessel they are contained in, gases have no definite shape.

Gases expand to fill the entire area that contains them. As a result, a gas will exert an equal amount of pressure on all surfaces of the vessel that contains it.

Pascals Law
Pascals Law states that when a force is applied to a confined fluid, the force will be transferred undiminished throughout the fluid to all surfaces of the containing vessel or tank.

Advantages of compressed air

AMOUNT

Air is available practically everywhere for compression, in unlimited quantities. Air can be easily transported in pipelines, even larger distances. It is not necessary to return the compressed air.

TRANSPORT

STORABLE

A compressor need not be in continuous operation. Compressed Air can be stored in and removed from a reservoir. In addition, transportation in the reservoir is possible.
Compressed Air is insensitive to temperature fluctuations. This ensures reliable operation, even under extreme conditions of temperature.

TEMPERATURE

Advantages of compressed air

(continued)

EXPLOSION PROOF

Compressed Air offers no risk of explosion or fire, hence no expensive protection against explosion is required. Compressed Air is clean since any air which escapes through leaking pipes or elements does not cause contamination. This cleanness is necessary, for example, in the food, wood, textile and leather industries. The operating components are of simple construction, and are therefore inexpensive. Compressed Air is very fast working medium. This enables high working speeds to be attained. (Pneumatic cylinders have a working speed of 1 to 2 Meters/Second).

CLEANLINESS

CONSTRUCTION

SPEED

Advantages of compressed air

(continued)

ADJUSTABLE

With compressed air components, speeds and forces are infinitely variable.
Pneumatic tools and operating components can be loaded to the point of stopping and they are therefore overload safe.

OVERLOAD SAFE

Disadvantages of compressed air

PREPARATION The Compressed Air needs good preparations. Dirt and humidity may not be present. (Wear of Pneumatic Components).
It is not possible to achieve uniform and constant piston speeds with compressed air. Compressed Air is economical only up to a certain force requirement. Under the normally prevailing working pressure of 700 KPa (7 Bar / 101.5 PSI) and dependent on the travel and speed. The limit is between 20,000 and 30,000 N (2,000 and 3,000 Kg.f).

COMPRESSIBLE

FORCE REQUIREMENT

Disadvantages of compressed air

(continued)

EXHAUST AIR

The exhaust air is loud. This problem has now, however, been largely solved due to the development of sound absorption material.
Compressed Air is a relatively expensive means of conveying power. The high-energy costs are partially compensated by inexpensive components and higher performance. (Number of cycles).

COSTS

Some applications of Pneumatic Systems

Industrial robots (Automation) Operation of bus doors Operation of machine tools Operation of work holding devices Air tools

Some applications of Pneumatic Systems

Industrial robots (Automation) Operation of bus doors Operation of machine tools Operation of work holding devices Air tools

Benefits of Compressed Air

Explosion proof Fast Easily transportable Easily stored Overload safe Variable speed Variable pressure

Clean Simple construction Stroke setting No return lines Wide operating temperatures Others
(compact,light,repair)

A Basic Pneumatics System

Intake air filter

Air Receiver

Compressor
After cooler Air separator Pressure switch Safety valve

Air service unit

Directional valves Actuators

Summary of Energy Supply

Plant
Filter Pressure Regulator Lubricator

Service Unit

Piping System

Ring Circuit Gradient 1-2% Tapping Outlets pointing upwards Diameter

Dryer

Cooling (note: Dew Point) Absorption Adsorption

To dampen pressure fluctuation Condensation of water vapor Safety Types of Compressor (Positive displacement, Flow Compressor) Flow Rate Pressure Service

Receiver

Compressor

Summary of Energy Supply

Plant

Service Unit

Compressors are required to compressed the gas to the desired working pressure for transmission of power.

Piping System

Dryer

Receiver
Types of Compressor (Positive displacement, Flow Compressor) Flow Rate Pressure Service

Compressor

Summary of Energy Supply

Plant

Service Unit

Compressed Air Receiver serves to stabilized the air supply and smoothens pressure fluctuations in the network when air is consumed.

Piping System

Dryer
To dampen pressure fluctuation Condensation of water vapor Safety

Receiver

Compressor

Summary of Energy Supply

Plant

Good preparation is important when using compressed air. Water (moisture) is introduced in the system by the compressor which should be dealt with at the point of usage.

Service Unit

Piping System
Cooling (note: Dew Point) Absorption Adsorption

Dryer

Receiver

Compressor

Air Drying
Refrigeration Drying

Air outlet

If the temperature is lowered further, the water vapor contained in it begins to condense.

Air inlet

Refrigerating unit

Air to air-heat exchanger

Moisture separato r

Refrigerant
Refrigeration machine

Moisture separator

Dew Point Curve

Example: At a dew point of 40C (313K), the quantity of water in 1M air is 50 Grams.

Air Drying
Absorption Drying Moisture, gases or dissolved

(continued)

Dry air outlet

materials from the air combines with the desiccant to form into a solid or liquid state. It is a chemical process and no external energy is required.
Simple installation but high operating cost because the desiccant have to be discarded.
Moist air inlet

Desiccant

Condensate

Condensate drain

Air Drying
Adsorption Drying

(continued)

Prefilter (oil filter)

Moisture, gases or dissolved materials from the air deposits on the

Shut-off valve (open)

Shut-off valve (closed)

porous surface of the desiccant. It is a physical process and regeneration is possible through hot air flow.

Adsorber 1

Adsorber 2

Hot air Shut-off valve (open) Shut-off valve (closed) Secondary filter

Heater

Blower Dry air

Summary of Energy Supply

Plant

Service Unit

Piping System

Gradient 1-2% Tapping Outlets pointing upwards Diameter Ring Circuit

Dryer

Condensation in the system should be prevented. Condensate can be trapped in pipelines at lowest points. Pipelines should be installed with downward gradient, measured in the direction of flow. Piping diameter should be selected primarily on the basis of flow volume, pipe length and working pressure.

Receiver

Compressor

Installation of Pipelines

Branch Line

Ring circuit are the commonly used pipeline installation. Gas can flow from two direction and a uniform supply can be obtain where there is heavy consumption.

Inter-connected System

Ring Circuit

Summary of Energy Supply

Plant
Filter Pressure Regulator Lubricator

Service Unit

Piping System

Dryer

Compressed air needs good preparation. Dirt and humidity should be prevented as it may wear pneumatic components or

Receiver

cause it to malfunction.

Compressor

Service Units

Compressed Air Filter Combined Symbols - Air Service Units

Filter with Water Trap Manual Control

Filters remove contaminants, mainly condensed water from compressed air. Compressed air is conducted into the filter bowl and is rotated at high speed. Heavy particles of dirt and water particles are centrifuged onto the wall of the filter bowl and they remain there. Condensed water accumulates in the lower part of the filter bowl and is drained through the drain plug when the water reaches the maximum level mark. Fine particles are retained by the filter element through which the air has to flow.

Outlet

Inlet Baffles Filter Element Water Trap Drain

Service Units

Pressure Regulating Valve with Relief Port

Pressure Regulator with Relief Port

Inlet

Outlet

Pressure operation

Valve Body

Vent Spring and

Adjusting screw

Operation of Pressure Regulator with Relief Port

6 Bar

The set screw permits adjustment of the initial tension in the diaphragm spring. The diaphragm lifts off the push rod off its seat. The push rod shuts off the exhaust port in the diaphragm.

Operation of Pressure Regulator with Relief Port

4.5 Bar

6 Bar

If the pressure in the volume with the output port exceeds the set value, the diaphragm moves down first, shutting off the input port and then opening the exhaust ports to relieve the excess pressure.

Service Units

Compressed Air Lubricator

Lubricator

Air flows through the lubricator from left to right. Some of the air flowing through the valve is guided through a nozzle. Due to the resulting pressure drop, oil is drawn from an oil reservoir through a feed pipe.

Lubricator

The air lubricator is used when -Extremely rapid oscillating motions are required
-With cylinders with large diameters(125mm)

The Structure of Pneumatic Systems

Command Execution Signal Output

Control elements: Directional control valves

Working elements: Cylinders Motors Optical indicators

Signal processing

Processing elements: Directional control valves, Shuttle valves, Dual-pressure valves, Sequencers, Pressure sequence valves

Signal input

Input elements: Push-button directional control valves Roller lever valves, Proximity switches, Air barriers

Energy supply

Energy supply elements: Compressor Pneumatic reservoir Pressure regulating valve, Service units

System Circuit Diagram

1A 1S3

Working element
1V2 4

2
12

Control element Processing element

1S1
2

14

1V1
1

2 1(3 ) 5 3 1

1S2

1S3

Input elements
1 3 1 3 1 3

0Z 0S

Energy supply elements

Symbols for the Power Supply Section

Energy Supply:

Pressure Source

Compressor with constant displacement volume

Pneumatic reservoir

Maintenance:

Filter

Water separator with manual actuation

Water separator with automatic condensate drain

2

1 3

Lubricator

Pressure regulating valve with relief port, adjustable

Combined Symbols:

Air Service Unit (consisting of: Compressed air filter, Pressure regulating valve, Pressure gauge and compressed air lubricator)

Symbols for Control Elements

Non-return, Flow Control and Pressure Control Valves

Symbols for the Principle Working Elements

Linear Actuators:

Single-acting cylinder

Double-acting cylinder

Double-acting cylinder with through piston rod

Double-acting cylinder with single, Double-acting cylinder with non-adjustable cushioning adjustable cushioning at both ends

Rodless cylinder with magnetic coupling

Air motor, constant displacement, rotation in one direction Rotary Drives:

Pneumatic rotary motor

Air motor, variable displacement, rotation in one direction

Air motor, variable displacement, rotation in both directions

Design Characteristics of Directional Valves

The design principle is a contributory factor with regards to service life, actuating force, means of actuation, means of connection, and size.

Valve designs are categorized as follows:

Poppet Valves

Ball Seat Valve

Disc Seat Valve Longitudinal Slide Valve Longitudinal Flat Slide Valve Plate Slide Valve (Butterfly Valve)

Slide Valves

Ball Seat Poppet Valve

3/2-Way Valve: Ball Bearing Seat, Normally Closed Position

Disk Seat Poppet Valve

3/2-Way Valve: with Disk Seat, Normally Closed Position

Longitudinal Slide Valve

5/2-Way Double Pilot Valve, Pneumatically Actuated, Both Sides 5 Working ports, 2 switching positions The valve has a memory function. A short signal (pulse) is sufficient for actuation.

Longitudinal Flat Slide Valve

4/3-Way Valve, Mid-Position Closed, (flat slide valve) 4 Working ports, 3 switching positions Flat slide valves are mostly actuated manually as other types of actuation can only be implemented with difficulty. By rotating two disks, the flow channels are connected with, or isolated from each other.

SWITCHING SYMBOLS FOR VALVES

The valve switching position is shown by a square.

The number of squares corresponds to the number of switching positions.

Lines indicate the flow paths, arrows indicate the direction of flow.

Closed ports are shown by two lines drawn at right angles to one another.

The connecting lines for supply and exhaust air are drawn outside the square.

Directional Control Valves: Ports and Switching Positions

Number of ports Number of switching positions

2/2-way valve, normally open position 3/2-way valve, normally closed position

3/2-way valve, normally open position

4/2-way valve, flow from 1 to 2 and from 4 to 3

5/2-way valve, flow from 1 to 2 and from 4 to 5

5/3-way valve, mid-position closed

Valve Connections Labeling

Connection Coding Working or Outlet ports Power Connection Drain, Exhaust Ports Leakage Line

As per ISO 1219 A, B, C P R, S, T L

As per ISO 5599 2, 4, 6 1 3, 5, 7... 9

Control Lines

X, Y, Z

12, 14, 16

PORT DESIGNATIONS

Port designation in accordance with DIN ISO 5599-3 "Fluid Technology Pneumatics, 5-Way Valves" 1 2, 4 3, 5 -Supply port -Working ports -Exhaust ports 10 12 14 81, 91 -Signal applied blocks flow from 1 to 2 -Signal applied opens flow from 1 to 2 -Signal applied opens flow from 1 to 4 -Auxiliary pilot air