INTRODUCTION TO

PNEUMATICS

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 PNEUMATICS
It was derived from the Greek word ‘pneuma’ which means ‘to breath’.

A Branch of fluid power which uses compressed air or other gases to transmit
power and to control systems

In electricity, the medium used to transmit power is through electric current (that
is electron charges); in hydraulics the medium used is liquid (which is usually
oil); in mechanics the medium used is the mechanical motion and force itself.

Because air and other gases moves or diffuses fast, pneumatics is highly used
in automatic assembly equipment.

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 ADVANTAGES OF PNEUMATIC
SYSTEMS

Availability. Air is available practically everywhere

Transport. Only needs pipelines even for long distances

Storage. Compressed Air can be stored in air reservoir/tank

Temperature Insensitive. Relatively insensitive to temperature fluctuations

Explosion-Proof. Compressed Air is non-combustible

Cleanliness. Air is clean

Speed. Air moves or diffuses fast

Overload-Safe. Components can be loaded even to the point of stopping

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 DISADVANTAGES OF PNEUMATIC
SYSTEMS

Preparation. Needs thorough preparation to filter dust, dirt and ensure constant pressure

Non-Uniform Speed. It is always not possible to achieve uniform speeds

Non-Uniform Force and Torque. It is always not possible to achieve uniform force/torque

Force Requirement. Used only for relatively small load (<50kN)

Noise Level. Compressed Air is very noisy

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 COMPARISON OF VARIOUS WORKING
MEDIA

CRITERIA PNEUMATICS HYDRAULICS ELECTRICS

Lower forces
compared to
Large forces due to
Force limited due to hydraulics but
high pressure; no
low pressure; no higher than
FORCE (LINEAR) energy
energy consumption pneumatics; poor
consumption during
during stoppage efficiency; high
stoppage
energy consumption
during stoppage
Large torque due to
Torque limited due
high pressure; full
to low pressure; no
torque even during Minimal torque
FORCE (ROTATING) energy consumption
stoppage but during stoppage
and full torque
increased energy
during stoppage
consumption
Complicated and
Simple generation, Simple generation,
expensive due to
MOVEMENT, LINEAR high acceleration, low acceleration,
conversion by
high speed low speed
mechanical means

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 COMPARISON OF VARIOUS WORKING
MEDIA

CRITERIA PNEUMATICS HYDRAULICS ELECTRICS

Compressed air
motors with Hydraulic motors
Greatest efficiency
MOVEMENT, extremely high and swivel cylinders
for rotary drives;
ROTATING speeds, high with lower speeds
speed is limited
operating costs, poor but high efficiency
efficiency
Excellent
Easy adjustability of
adjustability of force
force via pressure
and speed, can be High cost for
ADJUSTABILITY and of speed via
accurately adjusted adjustability
volume flow even in
even in slow speed
lower speed range
range
Difficult and
expensive in storing
Large quantities
ENERGY STORAGE & Only limited storage huge energy; easily
possible, easily
TRANSPORT possible transportable over
transportable
great distances via
transmission lines
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 COMPARISON OF VARIOUS WORKING
MEDIA

CRITERIA PNEUMATICS HYDRAULICS ELECTRICS

Sensitive to
Resistant to temperature
temperature fluctuations Highly resistant to
ENVIRONMENTAL fluctuations, no (viscosity is a temperature
EFFECTS explosion hazard; function of temp.); fluctuations; Fire and
Risk of icing in high fire risk in the event explosion hazard
humidity of leakage and
contamination
Too high compared Too high compared
ENERGY COSTS Lower energy costs
to electricity to electricity
SPACE LARGER THAN
SMALL LARGE
REQUIREMENTS PNEUMATICS

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 PHYSICAL
FUNDAMENTALS AND
PRINCIPLES BEHIND
PNEUMATICS

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 PRESSURE

The amount of molecules contained per unit volume of space [the more
molecules there are in a volume of space, the higher is the pressure]

Because these molecules in fluid are free to move, they collide with each other
and also to the walls of the container they are contained in. As a result their
collisions translate to a force that causes motions.

The higher the concentration of molecules per unit volume, the higher is the
pressure then the higher is the resulting force.

F=P*A unit: [N/m2 * m2 = N]

Also since these molecules collide with a surface area, the larger the area the
more distributed the collision is, then the higher is the total force.

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 PRESSURE

Units of pressure:
Bar kPa psi Rules of thumb
0.069 7 1
1 100 14,5 1 bar = 100 kPa = 14.5 psi
(100 000 Pa)
2 200 29
3 300 43.5 1 Pa = 0.00001 bar = 0.000145 psi

4 400 58
5 500 72.5 1 psi = 0.069 bar = 6897.8 Pa

6 600 87
7 700 101

Atmospheric pressure is 1.01325 bar = 101.325 kPa = 14.7 psi above absolute
zero at sea level, pressure drops as elevation from ground/sea level increases.

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 PRESSURE

PRESSURE READING:

Pressure can be read by various pressure metering device (manometer,

barometer, bourdon tubes, bellows, etc)

All readings are above atmospheric pressure which is termed the gauge
pressure

Special type of pressure gauges measure absolute pressure not gauge

pressure, so pressure below atmospheric pressure can be obtained (called
vacuum pressure)

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 Samples of industrial gauges

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 BOYLE’s LAW

The relationship between pressure and the containing volume setting aside or
neglecting the effect of temperature [eg. temperature is held constant]

p1*V1 = p2*V2 = p3*V3 = constant

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 GAY-LUSAAC’s LAW

The relationship between pressure and temperature in a constant volume [eg.

volume is unchanged]

P1 / T1 = p2 / T2 = p3 / T3 = constant

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 HUMIDITY
Water content (water vapor) in air

ABSOLUTE HUMIDITY
Actual quantity (mass) of water vapor in one m3 of air (volume)
SATURATION QUANTITY / SATURATED VAPOR PRESSURE
Maximum quantity (mass) of water vapor that one m3 of air (volume) can
absorb which depends upon the temperature
RELATIVE HUMIDITY
Ratio of absolute humidity to the maximum (saturation quantity) and
usually expressed as percentage %

“Relative humidity is then 100% max. and the temperature at this point is
called dew point temperature”
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 DEW POINT CURVE

Example:

1.) At a dew point of

313K (400C), the quantity
of water in one m3 air is
50 grams

2.) At a dew point of

293K (200C), the quantity
of water in one m3 air is
17.3 grams

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 ENERGY SUPPLY

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 ENERGY SUPPLY – COMPRESSED AIR SUPPLY

I. AIR GENERATION
II. AIR DISTRIBUTION
III. AIR PREPARATION

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 AIR GENERATION

To provide pneumatic systems with high pressure of air, compressed air must
be generated, that is air must be COMPRESSED

Compressors provide pneumatic systems with the operating pressure from the
atmospheric pressure via air compression. They act as energy source for
pneumatic systems.

ATMOSPHERE COMPRESSOR PNEUMATIC SYSTEMS

p = 0 bar S p = 5 - 7 bar

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 AIR GENERATION

Cools the air and removes condensed water and also compressor lubrication oil

It usually comes after compressor (downstream of compressor)

ATMOSPHERE AFTERCOOLE PNEUMATIC SYSTEMS

p = 0 bar COMPRESSORS
R p = 5 - 7 bar

Circuit Symbol:

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 AIR GENERATION

To store compressed air from compressor, an AIR RECEIVER or AIR

RESERVOIR is used

Air receivers or reservoir provides many functions:

• It levels out surges from compressor or pneumatic devices
• Compressor can stop or pause when pressure is achieved
• Its large surface area causes water vapor to condense and be drained

ATMOSPHERE AFTERCOOLE AIR

p = 0 bar COMPRESSORS
R RECEIVER

PNEUMATIC SYSTEMS
p = 5 - 7 bar
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 AIR GENERATION

But even after AFTERCOOLING and cooling and water separation in the AIR
RECEIVER, there is still a residue of moisture in the air; that is why an AIR
DRYER is used.

ATMOSPHERE AFTERCOOLE AIR

p = 0 bar COMPRESSORS
R RECEIVER

PNEUMATIC SYSTEMS AIR DRYER

p = 5 - 7 bar

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 COMPRESSORS
There are various type of compressors depending upon its design
The most common are reciprocating compressors and screw compressors

Circuit Symbol

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 MULTI-STAGE RECIPROCATING COMPRESSORS
Used to attain higher operating pressure and to provide cooling of the
compressed air

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 Types of compressors

• Reciprocating piston compressor

• Rotary piston compressor
• Flow compressor
• Piston compressor
• Diaphragm compressor
• Radial-flow compressor
• Axial flow compressor
• Sliding vane rotary compressor
• Two-axle
• Screw
• Compressor
• Roots blower

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 Piston compressor

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 Piston compressor

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 Piston compressor

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 Piston compressor

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 Piston compressor

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 Piston compressor

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 Piston compressor

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 Piston compressor

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 Screw compressor

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 Axial compressor

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 Axial compressor

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 Axial compressor

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 Aftercooler

To combat the effects of moisture or humidity in air that affects pneumatic

systems, an AFTERCOOLER is used

Moisture in air causes many problems in pneumatic systems like corrosion and
flow rate of air

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 Air receiver

Air receivers are used for

• Providing constant air pressure in a pneumatic system regardless of fluctuating consumption
• Emergency supply to the system in cases of emergency
• The large surface area cools the air
• Moisture can be separated from the air

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 AIR RECIEVER / AIR RESERVOIR

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 AIR RECIEVER / AIR RESERVOIR
Air receivers are not used for permanent storage of air and is always located
downstream of air compressors

Circuit Symbol

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 Air dryers

Water produces
• Hardening of seals
• Corrosion
• Washing out of original lubrication of cylinders
• Swelling of seals and diaphragms

Therefore air dryers are used to reduce the moisture content.

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 AIR
DRYER
There are three basic types of air dryers depending upon how it dries the air
The most commonly used in industries is refrigeration drying

Circuit Symbol

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 REFRIGERATION
DRYING
Air is passed to a heat exchanger system through which a refrigerant flows
Reduces temperature to a low dew point

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 Air dryers

Commonly used air dryers are :

• Low temperature drying
• Adsorption drying
• Absorption drying

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 Low temperature drying

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 Adsorption drying

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 Absorption drying

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 ENERGY SUPPLY – COMPRESSED AIR
SUPPLY

I. AIR GENERATION
II. AIR DISTRIBUTION
III. AIR PREPARATION

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 AIR DISTRIBUTION

Compressed air must be supplied or distributed to consuming devices through a

compressed air network

Compressed air network is structured using pipelines.

Two types of air distribution lines:

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 Piping system (air distribution)

Diameter of pipe-lines depends on:

• Flow volume
I.e. Volume diameter
• Pipe length
I.e. Longer length diameter
Otherwise, pressure drop is high
• Pressure drop
Permissible pressure drop between receiver and user should not be more than 0.1 bar

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 Piping system (air distribution)

• Working pressure
Should not be more than 0.1 bar.
• Number of restrictions
I.e. Number of resistance to flow; Example: shut-off valves, bends, t-joints, etc.

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 Air distribution

1-2% Gradient

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 Air distribution (air ring main)

Production
Plant

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 Air distribution (ring main cross-connected)

Production
Plant

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 DIMENSIONING OF PIPELINES

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 DIMENSIONING OF PIPELINES
Guidelines:

The smaller the pipeline diameter is, the higher is the frictional loss causing
decrease in pressure.

The larger the pipeline diameter is, the lower the build-up of pressure at the
consuming devices

Dimensioning should allow increases for compressed air consumption

(allowance for possible future requirements)

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 PIPING MATERIAL
Plastic and steel are the main raw materials used for
piping

PLASTIC PIPE STEEL PIPE

Inside surface is smoother, so Stronger -> can handle higher

it causes less friction pressure
Lighter Relatively cheaper
Non-corrosive More heat-resistant
Can be joined cleanly by
gluing together

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 ENERGY SUPPLY – COMPRESSED AIR
SUPPLY
I. AIR GENERATION
II. AIR DISTRIBUTION
III. AIR PREPARATION

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 AIR PREPARATION
After air is generated and distributed to individual pneumatic systems, it must
first be properly prepared before being used by individual pneumatic components
to ensure problem-free operation
PNEUMATIC PNEUMATIC
SYSTEM SYSTEM

AIR AIR
PREPARATION PREPARATION

AIR @ ATMOSPHERIC AIR

PRESSURE GENERATION
AIR
PREPARATION

PNEUMATIC
SYSTEM
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 AIR PREPARATION

I. FILTER
II. PRESSURE REGULATOR
III. LUBRICATOR

FILTER + PRESSURE REGULATOR + LUBRICATOR = SERVICE

UNIT

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 FILTER

Filter cleans the compressed air by removing impurities:

1. dust
2. small particles
3. pipe scales
4. rust
5. water condensate
6. oil

Circuit Symbol:

w/o water drain w/ water drain

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 PRESSURE REGULATOR

Used to obtain uniform operating pressure for the pneumatic system in order to:

1. obtain uniform speed

2. obtain uniform force and torque

Circuit Symbol:

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 LUBRICATOR
Enriches the compressed air with a fine oil mist (that is a lubricant) to make
movements smoother especially on drive components

It should however be used sparingly to avoid clogging of narrow passages

(example in valves). Some industries also like semiconductor and food industries
require oil-free air to avoid contamination.

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 LUBRICATOR

Circuit Symbol:

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 SERVICE UNIT

A service unit which consists of filter, regulator and lubricator (optional) must
always be present upstream of every individual pneumatic system

Circuit Symbol:

w/ Lubricator

w/o Lubricator

Complete Simplified

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 Air service unit

The air service unit consists of

• Air filter
• Pressure regulator
• Air lubricator
• Pressure gauge

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 Air Filter

The air filter is used for

• Preventing dirt particles from entering into the system
• Separate condensate out of the compressed air

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 Air filter

Pressure
regulator Baffl
e

Filter

Condensate

Lubricator Filter
bowl
Filter unit Drain
screw

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Types and sizes of contamination

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 Air filter

Inlet Outlet

Filter
Baffles
Element

Water Trap

Drain
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 Micro filter

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 Pressure regulator

The pressure regulator is used

• To provide a constant supply pressure irrespective of the pressure fluctuations in the main
line

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 Pressure regulator

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Pressure regulator

Inlet Outlet
Pressure operation

Valve Body

Spring
Vent

Adjusting screw

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Pressure regulator

6 Bar

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Pressure regulator

6 Bar

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Pressure regulator

6 Bar

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Pressure regulator

6 Bar

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 Pressure regulator 4 Bar

6 Bar

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 Pressure regulator

6 Bar

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 Pressure regulator

6 Bar

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 Pressure regulator

6 Bar

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 Pressure regulator

6 Bar

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 Pressure regulator

6 Bar

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Pressure regulator 4 Bar

6 Bar

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 Pressure regulator 4 Bar

6 Bar

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 Pressure regulator 4.5 Bar

6 Bar

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 Pressure regulator
4.5 Bar

6 Bar

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 Pressure regulator

6 Bar

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 Air lubricator

The air lubricator is used

• Extremely rapid oscillating motions are required
• With cylinders with large diameters ( 125mm diameter)

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 Air lubricator

Viaduct
Drip
chamber

Duct

Check valve
Ball seat

Pressure
regulator

Riser

Oil

Lubricator

Filter unit

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 Air lubricator

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 Air lubricator

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 Air service unit

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 Air service unit

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 Air service unit symbol

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