INTRODUCTION

TO
PNEUMATICS

PNEUMATICS
Technology of Pneumatics deals with the study of the behavior and
application of compressed air
Science of air is known to man for centuries
Not used in industry before the beginning of the Second World war
(1939-44)
Many industries all over the developed western countries started
switching over to more & more automatic equipment and machineries
Origin of Pneumatics Manufacturing & other activities to meet the
sudden need of enhanced production of war commodities under the
tremendous shortage of skilled manpower (concept of automation)
Cheaper medium of Industrial automation
Maximum application of pneumatics Construction (power hammers,
drills, riveting hammers, pneumatic cranes, air brakes, printing presses
etc.)

PNEUMATICS Notable Features

Wide availability of air
Compressibility of air
Easy transportability
Explosion proof characteristics of the medium
Simple construction of pneumatic elements and easy handling
High degree of controllability of pressure, speed and force
Possibility of easy but reasonably reliable remote controlling
Easier maintenance
Comparatively cheaper in cost than other systems

PNEUMATICS Physical Principles

Earth is surrounded by air up to a height of approximately 1600 km
above the top surface of the earth
Gaseous layer of air around the earth is known as atmosphere
Main constituents of air by volume
- Nitrogen
: 78%
- Oxygen
: 21 %
- Carbon dioxide & other gases : 1%
Air which is a mixture of various chemical elements follows the gas
laws.

GAS LAWS

GAS LAWS

PNEUMATICS REVIEW
Played an important role as a Technology in the performance of
Mechanical Work
In the majority of applications compressed Air is used for one or more
of the following functions
- To determine status of the processor (sensor)
- Information processing (processors)
- Switching of actuators by means of final control elements
- Carrying out work (actuators)
Interaction of all the above governs installation and control of
machinery

PNEUMATICS REVIEW

PNEUMATICS REVIEW

APPLICATIONS

APPLICATIONS

APPLICATIONS

Pneumatic Bending device

USAGE OF PNEUMATICS

ADVANTAGES & CHARACTERISTICS

OF COMPRESSED AIR

DISADVANTAGES OF PNEUMATICS

GENERAL FACTORS FOR COMPARING

OTHER FORMS OF ENERGY

CRITERIA FOR WORKING MEDIA

Power requirements
Temperature variations

CRITERIA FOR CONTROL MEDIA

PNEUMATICS & CONTROL

SYSTEM DEVELOPMENT

STRUCTURE & SIGNAL FLOW OF

PNEUMATIC SYSTEMS

STRUCTURE & SIGNAL FLOW OF

PNEUMATIC SYSTEMS

PNEUMATIC CONTROL SYSTEM

BREAKDOWN OF CONTROL CHAIN

CIRCUIT DIAGRAM & PNEUMATIC ELE.

BASIC REQUIREMENTS FOR

INTRODUCING PNEUMATICS IN A PLANT
1.

Compressor plant

2.

Pipeline

3.

Control valves

4.

Air actuator

5.

Auxiliary appliances

COMPONENTS PNEUMATIC SYSTEM

COMPARISION

COMPARISION

COMPARISION

COMPARISION

PNEUMATIC
ACTUATORS

PNEUMATIC ACTUATORS
Similar to Hydraulic actuators
Converts air pressure into linear or rotary motion
Used for variety of applications such as Gripping, Pulling or pushing
of objects
CLSSIFICATION
Linear actuators ( air cylinders)
- Single acting
- Double acting (Normal, Double rod, Turn cylinder, Tandem
cylinder, Multi-position cylinder)
- Ram cylinders
- Single rod
- Rod-less cylinders
- Diaphragm cylinders
- Rolling diaphragm cylinder
Rotary actuators ( air motors)
- Vane type Semi-rotary actuator
- Rack & pinion type actuator
- Rotary cylinder type actuator

SINGLE ACTING CYLINDER

SINGLE ACTING CYLINDER

PNEUMATIC ACTUATORS

PNEUMATIC ACTUATORS

PNEUMATIC ACTUATORS

PNEUMATIC ACTUATORS

PNEUMATIC ACTUATORS

PNEUMATIC ACTUATORS

DOUBLR ROD NON-ROTATING CYLINDER

PNEUMATIC ACTUATORS

ROTARY CYLINDER

ROD-LESS CYLINDERS
Three different operational principles used for construction of rodless
cylinders are
- Sealing band cylinder
- Band or cable cylinder
- Cylinder with magnetic coupling

SEALING BAND CYLINDER

ROD-LESS CYLINDERS

BAND or CABLE CYLINDER

ROD-LESS CYLINDERS

CYLINDER WITH MAGNETIC COUPLING

ROTARY CYLINDER TYPE ACTUATOR

DESIGN PARAMETER - SELECTION

1.

Size

2.

Speed

3.

Environmental protection

4.

Maintenance

5.

Direction reversal

Previously Discussed Bits..

End position cushioning
Seals
Mounting arrangements

DIRECTIONAL
CONTROL
VALVES

PNEUMATIC CONTROLS
PURPOSE OF VALVE
For controlling the to and fro motion of a pneumatic cylinder, the air
energy has to be regulated, controlled and reversed with a
predetermined sequence in a pneumatic system
Control of pressure and flow
VALVE DEFINATION
Fluid power elements used for controlling and regulating the
working medium
VALVE USAGE

To start & stop pneumatic energy

Control the direction of flow of compressed air
Control the flow rate of the compressed air
Control the pressure rating of the compressed air
VALVE TYPES
1. DCV
2. Non-return valves
3. FCV
4. PCV

DIRECTION CONTROL VALVES

Used mainly to direct the flow of the pressure fluid in the desired
direction
Main function To start, stop and regulate the direction of air flow
and help distribution of air in the desired line
DCVs has generally 2, 3, 4, or 5 ports / openings / ways
Ways are designated by letters or alphabets such as :
P
= Compressor line port
R
= Exhaust port
A&B
= working ports to cylinders or motors
DCVs are basically classified as
- Seat or poppet valves
- Spool or sliding valves

SEAT Vs SPOOL VALVES

SEAT / POPPET
TYPE VALVES

3/2 SEAT TYPE VALVE

4/2 SEAT TYPE

SPOOL / SLIDING
TYPE VALVES

2/2 SPOOL VALVE

3/2 SPOOL VALVE

4/2 SPOOL VALVE

5/2 DCV

5/2 PILOT OPERATED DCV

5/3 WAY VALVE

SUSPENDED SEAT TYPE VALVE

CONTROL

ACTUATION
OF VALVES

SPEED
REGULATORS

FIXED TYPE FCV

NON-RETURN TYPE FCV

CHECK VALVE

TWIN PRESSURE VALVE

TWIN PRESSURE VALVE - USAGE

SOLENOID OPERATED
VALVE (3 WAY)

SIMPLE
PNEUMATIC
CONTROL

ISO SYMBOLS FOR FLUID CIRCUITS

ELECTRICAL SYMBOLS
USED IN
PNEUMATIC CIRCUITS

PNEUMATIC CIRCUITS

DIRECT CONTROL

DIRECT ACTUATION

INDIRECT ACTUATION

PILOT CONTROL OF A SINGLE ACTING CYL.

PILOT CONTROL OF A DOUBLE ACTING CYL.

SPEED CONTROL SINGLE ACTING CYL.

SPEED CONTROL DOUBLE ACTING CYL.

AIR PILOT CONTROL DOUBLE ACTING CYL.

SEMI AUTOMATIC CONTROL DOUBLE ACTING

TWO STEP SPEED CONTROL OF A CYLINDER

ACTUATION OF A PNEUMATIC MOTOR

AUTOMATIC TO & FRO MOTION OF A

DOUBLE ACTING CYLINDER

SEQUENCING CIRCUIT

MEMORY VALVE

FLOW CONTROL VALVE

FLOW CONTROL VALVE

FLOW CONTROL VALVE

SUPPLY AIR THROTLLING

EXHAUST AIR THROTLLING

QUICK EXHAUST VALVE

QUICK EXHAUST VALVE

QUICK EXHAUST VALVE

QUICK EXHAUST VALVE

SIGNAL
PROCESSING
ELEMENTS

SYNOPSIS
Non-moving logic elements find a prominent place in Finer Control
Engineering
Characteristics offered by fluidic elements proves them to be at par
with electronic controls
Development of various fluidic elements conforms the need of logic
functions in Industrial Automation
Teslas fluid-diode & Theory of Wall-attachment Canada forms
the basic principle
Better control & feedback to the Pneumatic systems Use Logic
Gates along with power pneumatic circuits
Major area of application Field of Sensors

FLUIDICS
Susceptibility to wear & tear of mechanical parts Major problem in
Hydraulics and Pneumatics
Challenge Development of reliable control system without turning
towards Electronics
Specific need of control engineering forced engineers for a solution
within the fluid power system Development of new types of fluid
power elements in early 60s FLUIDIC ELEMENTS or FLUID
LOGIC ELEMENTS
Biggest advantage Minimum number of mechanical moving parts
(no wear & tear) NON-MOVING LOGIC CONTROLLERS
Much more reliable under adverse environmental conditions
(vibration, shock, heat, radiation, electromagnetic interference etc.)
Simpler in construction, Smaller in size, Mode of energy feeding is
very simple, Very little space to mount
Mostly employ working medium as AIR
Easily adoptable to Logic Functions

FLUIDICS
It is the study of the performance and
response characteristics of control
systems, computing devices and logical
switchgears based on fluidic elements
OR

The subject which deals with the area of

fluid logics is called fluidics

HISTORICAL BACKGROUND

Tesla invented a conduit in 1916 for fluids

Easy & Difficult floe direction owing to the interference caused by the
divided branch flow opposing the intended flow direction
Strong influence of electronics in this era accounts for the terminology
fluid-diode used to describe Teslas valved conduit
Real Development CONANDA EFFECT Named after Henri
Conanda Observed and reported WALL-ATTACHMENT
phenomenon

HISTORICAL BACKGROUND
WALL-ATTACHMENT
When a jet of fluid is pushed into an inclined wall, it will stay there,
even after the pushing control jet is removed (1933)
He noted that entrainment of the trapped air next to the surface of the
body over which it is moving creates a partial vacuum and the
atmospheric air forces the fluid stream to cling to the surface of the
solid over which the fluid is to travel
Existence of fluidic devices 60s - termed as fluid amplifier
Working pressure used for pneumatic fluidic devices is very less
within 0 to 0.05 to 0.1 bar

WHAT MAKES IT WORK?

BI-STABLE FLIP-FLOP

PNEUMATIC SIGNAL PROCESSING

Involves use of Pneumatic Logic Elements
Uses of air valves & other devices for control actions
Application of control actions to power systems to obtain the required
actuation
Conversion of minimum force to signals to operate high pressure
control valves

LOGICS IN PNEUMATIC CIRCUIT DESIGN

Logic Controls Design of control system based on reasoning arising
out of deductive principle
Famous Greek philosopher ARISTOTLE (384 322 BC) Father of
deductive logic

LOGIC FUNCTIONS
Pneumatic Shuttle valve and Dual pressure valve
have logic functions
Both have two inputs and two outputs each
Shuttle valve characteristic OR function
Dual pressure valve characteristic AND function

COMMON LOGIC FUNCTIONS

Memory

COMMON LOGIC FUNCTIONS

COMMON LOGIC FUNCTIONS

Time Dependent Limited Memory

COMMON LOGIC FUNCTIONS

AND Function

LOGIC FUNCTIONS & BOOLEAN ALGEBRA

LOGIC AND FUNCTION

Logic Symbol

Logic Equation

Truth Table

LOGIC AND FUNCTION

Pneumatic Symbol

PROBLEM - 1

LOGIC
AND
FUNCTION

SOLUTION

ALTERNATIVE
SOLUTION

PROBLEM - 2

POSITIONAL
SKETCH

LOGIC OR FUNCTION
Logic Symbol

Logic Equation

Truth Table

LOGIC OR FUNCTION

Pneumatic Symbol

LOGIC OR FUNCTION
PROBLEM - 3

SOLUTION

LOGIC OR FUNCTION
PROBLEM - 4

SOLUTION

PROBLEM - 5

POSITIONAL SKETCH

PRESSURE DEPENDENT CONTROL

PROBLEM - 6

SOLUTION

POSITIONAL
SKETCH

PRESSURE DEPENDENT CONTROL

PRESSURE DEPENDENT CONTROL

EMBOSSING OF PLASTIC COMPONENTS
PROBLEM - 7

POSITIONAL
SKETCH

TIME DEPENDENT CONTROL

In certain applications, the cylinder may have to be
retained in its extended position for a particular time
Automated Adhesive bonding operation
Usage of TIME DELAY VALVE

TIME DELAY VALVE

TIME DELAY VALVE - Symbol

TIME DELAY VALVE

PROBLEM - 8

SOLUTION

POSITIONAL SKETCH

PROBLEM - 9

POSITIONAL SKETCH

MULTICYLINDER
APPLICATIONS

INTRODUCTION

MOVEMENT DIAGRAM

TRAVEL TIME DIAGRAM

POSITION STEP DIAGRAM /

MOTION CONTROL DIAGRAM

POSITION STEP DIAGRAM OF A PNEUMATIC

CIRCUIT WITH TWO CYLINDERS

PNEUMATIC CIRCUIT AS PER

POSITION STEP DIAGRAM

POSITIONAL
SKETCH

DISPLACEMENT - STEP DIAGRAM

CIRCUIT DIAGRAM INITIAL POSITION

SOLUTION

Continued..

SOLUTION

Continued..

REPRESENTATION OF STEP - 1

REPRESENTATION OF STEP - 2

REPRESENTATION OF STEP - 3

REPRESENTATION OF STEP - 4

REPRESENTATION OF STEP - 5

CASCADE SYSTEM OF
PNEUMATIC CIRCUIT DESIGN

PRINCIPLE & PROCEDURE

PRINCIPLE & PROCEDURE

Continued..

FLOW LINES IN CASCADE SYSTEM

FIG. 10.6

PRINCIPLE & PROCEDURE

Continued..

POSITION STEP DIAGRAM FOR A 3

CYLINDER PNEUMATIC SYSTEM

FIG. 10.7

PRINCIPLE & PROCEDURE

Continued..

FIG. 10.8

CO-ORDINATED MOTION
PROBLEM - 1

SOLUTION

SEQUENTIAL MOTION CONTROL

INEFFECTIVE WAY

POSITION STEP DIAGRAM /

MOTION CONTROL DIAGRAM

LIMIT SWITCHES

EFFECTIVE WAY

POSITION STEP DIAGRAM /

MOTION CONTROL DIAGRAM

SIGNAL ELIMINATION BY
REVERSING VALVES

PROBLEM - 2

SOLUTION

SOLUTION

PROBLEM - 3

Continued..

POSITIONAL
SKETCH

DISPLACEMENT STEP DIAGRAM