H&P PNEUMATICS MK

Pneumatic systems use pressurized gasses to transmit and control power. Pneumatic systems
usually use air because of safety, low cost and readily available nature.
Reasons for considering pneumatic system instead of hydra ulic systems.
1. Liquid exhibit greater inertia than gases. Therefore, in hydraulic systems the weight of
the oil is a potential problem when accelerating and decelerating actuators and when
suddenly opening and closing valves.
2. Liquids also exhibit greater viscosity than gases. This results in larger frictional
pressure and power losses.
Hydraulic systems requires special reservoirs and no leak system design however pneumatic
system use air which are exhausted to atmosphere directly
Limitations:
1. Since air is compressible, it is impossible to obtain precise, controlled actuator
velocities with pneumatic systems.
2. Pneumatic systems are used for low power applications whereas hydraulic systems
are used for high pressure applications.
Areas of Use:
1. Industry
2. Trade
3. Rail transport
4. Motor vehicles
5. Mining
6. Shipping
7. Medicine
8. Construction and
9. Defense
Generation of rotary motions:
1. Screw drivers
2. Grinders
3. Thread cutters
4. Drills
5. Shears
6. Nibblers.
Application in Control:
1. sequence control
2. Monitoring
3. Protecting
4. Locking
5. Counting
6. Deceleration
7. Storage
8. Scanning
Others:
1. Workshop air
2. Spray painting
Extinguishers

SJCE Mech. Engg Dept Page 1

H&P PNEUMATICS MK

BASIC COMPONENTS OF PNEUMATIC SYSTEMS

Pneumatic system carries power by employing compressed gas generally air as a fluid for
transmitting the energy from an energy-generating source to an energy use point to
accomplish useful work. Figure shows the simple circuit of a pneumatic system with basic
components.

Functions of components

Pneumatic actuator converts the fluid power into mechanical power to do useful work

Compressor is used to compress the fresh air drawn from the atmosphere.

Storage reservoir is used to store a given volume of compressed air.

Valves are used to control the direction, flow rate and pressure of compressed air.

External power supply (Motor) is used to drive the compressor.

Piping system carries the pressurized air from one location to another.

Air is drawn from the atmosphere through air filter and raised to required pressure by an air
compressor. As the pressure rises, the temperature also rises and hence air cooler is
provided to cool the air with some preliminary treatment to remove the moisture.

Then the treatment pressurized air needs to get stored to maintain the pressure. With the
storage reservoir, a pressure switch is fitted to start and stop the electric motor when
pressure falls and reached the required level, respectively.

SJCE Mech. Engg Dept Page 2

H&P PNEUMATICS MK

The cylinder movement is controlled by pneumatic valve. one side of the pneumatic valve is
connected to the compressed air and silencers for the exhaust air and the other side of the
valve is connected to port A and Port B of the cylinder.

Position of the valve is as follows

1. Raise: To lift the weight , the compressed air supply is connected to port A and the port
B is connected to the exhaust line, by moving the valve position to the Raise

2. Lower: To bring the weight down, the compressed air line is connected to port B and port
A is connected to exhaust air line , by moving the valve position to the lower

3. Off: The weight can be stopped at a particular position by moving the valve to position to
Off position. This disconnects the port A and port B from the pressurized line and the
retrieval line, which locks the air in the cylinder.

Advantages of Pneumatic system

Low inertia effect of pneumatic components due to low density of air.

Pneumatic Systems are light in weight.
Operating elements are cheaper and easy to operate
Power losses are less due to low viscosity of air
High output to weight ratio
Pneumatic systems offers a safe power source in explosive environment
Leakage is less and does not influence the systems. Moreover, leakage is not harmful

Disadvantages of Pneumatic systems

Suitable only for low pressure and hence low force applications
Compressed air actuators are economical up to 50 kN only.
Generation of the compressed air is expensive compared to electricity
Exhaust air noise is unpleasant and silence has to be used.
Rigidity of the system is poor
Weight to pressure ratio is large
Less precise. It is not possible to achieve uniform speed due to compressibility of air
o Pneumatic systems is vulnerable to dirt and contamination

AIR PREPARATION

Pneumatic control systems operate on a supply of compressed air, which must be made
available in sufficient quantity and at a pressure to suit the capacity of the system. The
operational reliability and service life of a pneumatic system depend to a large extent on the

SJCE Mech. Engg Dept Page 3

H&P PNEUMATICS MK

preparation of the compressed air. Impurities in the compressed air such as scale, rust and
dust as well as the liquid constituents in the air which deposit as condensate can cause a great
deal of damage in pneumatic systems. These contaminants accelerate wear on sliding
surfaces and sealing elements, adversely affecting the functioning and service life of
pneumatic components. As a result of switching the compressors on and off, pressure
fluctuations occur which have an unfavourable effect on the functioning of the system. In
order to eliminate these effects, compressed air preparation should be given utmost
importance. There are four distinct stages of air preparation they are:

Stage 1 : This consist of air intake system

Stage 2: This stage consist of compressors, with drives controls, inter-cooling, compressor
cooling, waste heat recovery and air inlet filtration

Stage 3: This stage includes Conditioning equipment, consisting of air receivers, after
coolers, separators, traps ( also frequency called drain traps or drains) , filters and air dryers

Stage 4: This stage consist of air distribution subsystems, including main trunk lines, drops to
specific usage, valving, additional filters and traps(drains) , air hoses, possible supplement air
conditioning equipment, connectors, often pressure regulators and lubricator.

Stage 1 : An Intake filter removes larger particles which can damage the air compressor.

1. Location: The intake for a compressor will located either outdoors or indoors, whichever
provides the better air quality. Elevation of the compressor relative to sea level is required to
determine the atmospheric pressure and density of intake air. Air quality is judged by its
temperature, humidity and cleanliness. We must ensure that air intage is free of moisture or
pollution.

2. Intake Temperature: The density of air varies inversely with its temperature : an increase
in
delivery of approximately 1 percent is gained for -20 reduction of intake temperature.

Intake pipe material: The inside of intake piping must be smooth and not subject to
rusting or oxidation. Rust that flakes off will enter and damage the compressor.. Acceptable
intake air piping materials include plastic, cooper, stainless steel, aluminium or galvanized
steel. On metallic piping, mechanical couplings will be used. Welded joint must be avoided
since weld beads can break free, enter and damage the compressor.

SJCE Mech. Engg Dept Page 4

H&P PNEUMATICS MK

Critical pipe length: resonance of intake piping will reciprocating air compressor is
prevented by avoiding certain pipe lengths. These are called critical pipe lengths, and are a
function of the air temperature and the speed of the compressor in revolutions per minute.
Critical pipe lengths must be verified with equipment manufacturers.

Intake air filter: The selection of filter type is based on whether air compressor to be used
is lubricated or non lubricated, and on the quality of ambient air.

Viscous impingement filters have an efficiency of 85 to 90 percent of particle size

larger than 10 microns. This type of filter is acceptable for lubricated reciprocating
compressor operating under normal conditions

Oil bath filters have an efficiency of 96 to 98 percent of particle sized larger than 10
microns. This type of filter is more expensive, and for the most part no longer
recommended by compressor manufacturers, but may be considered for lubricated
reciprocating compressor operating under heavy duty conditions.

Dry filters have an efficiency of 99 percent of particles larger than 10 microns.

Because of their high filtration efficiency, these filters are the best selection for rotary
and reciprocating compressors. They must be used for non-lubricated compressors
and whenever air must be kept oil free.

Two stage dry filters , to provide 99 percent efficiency of particles larger than 0.3
micron, will be used for centrifugal units

With all types of filters, a means of monitoring the air pressure drop through the
element must be provided, which indicates element contaminations.

Stage 2: In this stage air is compressed using compressor. This book is not meant to be a
comprehensive analysis of all types of air compression system that can be designed. Instead,
it will concentrate on those most often found in industry and on thermodynamic analysis in
those systems. It will explore positive displacement types in great detail and dynamic
compressor in brief.

SJCE Mech. Engg Dept Page 5

H&P PNEUMATICS MK

Stage 3: In this stage outlet temperature at the compressor is reduced, solid contaminants
usually large than 100 micron are removed, and air is dried to reduce to its humidity. The
units used in the primary stage are after cooler, main line filter and dryer.

Stage 4: In this stage moisture and fine dirt particles are removed. In this stage pressure is
regulated to suit individual machines requirement and introduces the fine mist of oil to the
compressed air to aid lubrication. The units used in secondary air treatment are filter ,
regulator and lubricator ( Called FRL or service units)

Figure 1.1 shows all four stages of air preparation. Figure 1.2 illustrates a typical compressed
air system.

SJCE Mech. Engg Dept Page 6

H&P PNEUMATICS MK

Compressor:

A Compressor is a machine that compresses the air or another type of gas from a low inlet
pressure (usually atmospheric pressure) to a higher desired pressure level. Compressor
increases the pressure of the air by reducing its volume. Work required for increasing
pressure of air is available from the prime mover driving the compressor. Generally, electric
motor, internal combustion engine or steam engine, turbine etc. are used as prime movers.

SJCE Mech. Engg Dept Page 7

H&P PNEUMATICS MK

SINGLE CYLINDER COMPRESSOR

Piston compressors are available as single or double acting, oil lubricated or oil free with different
number of cylinders in different configurations. With the exception of really small compressors with
vertical cylinders, the V configuration is the most common for small compressors. On double acting,
large compressors the L type with vertical low pressure cylinder and horizontal high pressure
cylinder, offer immense benefits and is why this the most common design. The construction and
working of a piston type reciprocating compressor is very much similar to that of an internal
combustion engine.

Construction: Piston type compressor consists of cylinder, cylinder head, and piston with piston
rings, inlet and outlet spring loaded valves, connecting rod, crank crankshaft and bearings.

Operation

Compression is accomplished by the reciprocating movement of a piston within a cylinder. This

motion alternately fills the cylinder and then compresses the air. A connecting rod transforms the
rotary motion

SJCE Mech. Engg Dept Page 8

H&P PNEUMATICS MK

of the crankshaft into the reciprocating motion of piston in the cylinder. Depending on the application,
the rotating crank (or eccentric) is driven at constant speed by a suitable prime mover (usually electric
motor). Schematic diagram of single cylinder compressor is shown in Figure

Inlet stroke: -suction or inlet stroke begins with piston at top dead centre (a position providing a
minimum or clearance volume). During the downward stroke, piston motion reduces the pressure
inside the cylinder below the atmospheric pressure. The inlet valve then opens against the pressures of
its spring and allows air to flow into the cylinder. The air is drawn into the cylinder until the piston
reaches to a maximum volume position (bottom dead centre).The discharge valve remains closed
during this stroke

Outlet stroke: During compression stroke piston moves in the opposite direction (Bottom dead ctre
to top dead centre), decreasing the volume of the air. As the piston starts moving upwards, the inlet
valve is closed and pressure starts to increase continuously until the pressure inside the cylinder is
above the pressure of the delivery side which is connected to the receiver. Then the outlet valve opens
and air is delivered during the remaining upward motion of the piston to the receiver.

MULTI STAGE PISTON COMPRESSOR.

As per general gas laws, if the pressure increases temperature also increases. For example : if the exit
pressure of compressor is 5 bar in a single acting compressor, the compressor air temperature can rise
to over 200 and the motor power needed to drive the compressor rises. Therefore single stage
compressors are not used for high pressures. Multistage compressors are used when high pressures are

SJCE Mech. Engg Dept Page 9

H&P PNEUMATICS MK

required, because better cooling between stages can effectively increase the efficiency and reduce the
input power requirements.

Single stage machines compress the air to pressure of about 6 bars and in exceptional cases to 10 bars,
two stage machines normally discharge pressure up to 15 bars. Discharge pressures in the range of
250 bars can be obtained with high pressure reciprocating compressor of three and four stages.
In single stage compressor, entire compression of air takes place in single stroke of the piston. In
multi stage compressor, compression takes in stages. For maximum compressor efficiency, it is
desirable to cool air after one stage using inter- stage cooler. In two stage compressor, initial
compression takes place in the low pressure cylinder. Air from this stage (low pressure cylinder) is
passed through the inter cooler to reduce the temperature. Then the cooled air is compressed in the
high pressure cylinder.

Working:

Figure 1.11 shows the two stage (inline type) reciprocating air compressor. When the prime mover
connected to crank shaft rotates, crank rotates and the piston in the first stage reciprocates. It sucks the
air through the suction filter and inlet valve. The air, compressed to a certain degree passes from the
left cylinder to right cylinder through the intermediate cooler. The compression ratio in the first stage
is determined by the degree of cooling required.

Double acting Compressor:

SJCE Mech. Engg Dept Page 10

H&P PNEUMATICS MK

The pulsation of air can be reduced by using double acting compressor as shown in above Figure. It
has two sets of valves and a crosshead. As the piston moves, the air is compressed on one side whilst
on the other side of the piston, the air is sucked in. Due to the reciprocating action of the piston, the
air is compressed and delivered twice in one piston stroke. Pressure higher than 30bar can be
produced.

Rotary Air compressor:

Screw type air compressor:
These compressors work according to the displacement principles and deliver a continuous flow with
no pulsation or pressure fluctuations. As there are no intake or exhaust valves the compressor
requires very little maintenance. These are compact and allow a high rotary speed.

Sliding Vane compressor:

These are single shaft rotary compressor which work according to the displacement principle. Intake
and exhaust occurs via the sliding vane of an eccentrically mounted rotor which decreases the volume

SJCE Mech. Engg Dept Page 11

H&P PNEUMATICS MK

of the compression chamber from intake to exhaust. The output has a few pulsation and oil injection
is used for lubrication

Roots compressor:
The Roots type supercharger or Roots blower is a positive displacement lobe pump which
operates by pumping fluids with a pair of meshing lobes not unlike a set of stretched gears.
Fluid is trapped in pockets surrounding the lobes and carried from the intake side to the
exhaust. It is frequently used as a supercharger in engines, where it is driven directly from the
engine's crankshaft via a belt or, in a two-stroke diesel engine, by spur gears. Only low
pressures can be obtained by this principle. This is usually used in pneumatic conveying

SJCE Mech. Engg Dept Page 12

H&P PNEUMATICS MK

Conditioning and Storing Pneumatic System Air:

Atmospheric air contains dirt under even the best of operating conditions.
Pneumatic systems need to carefully filter the air taken into the compressor intake to
extend the service life of
Compressor
Other system components
Filters used on the intake line of pneumatic compressors may be
Dry element
Oil wetted
Oil bath
The filter used is based on the type of compressor, atmospheric conditions, and the final
use of the compressed air.
Air at construction sites is dirty.
Painting requires very clean air.

The temperature of both the intake and compressed air is important.

Temperature changes are reflected in air pressure and volume per the general gas law.
Temperature influences the ability of air to retain water vapor.
Air in a pneumatic system may be cooled before, during, or after compression.
Intake air temperature usually depends on the location of the compressor air intake
Intercoolers and after coolers are used to remove heat of compression

Liquid water in a pneumatic system can:

Wash away lubricants
Increase component wear
Cause inconsistent system operation
Lower the finished quality of products directly using the air in the
manufacturing process.
The receiver is the storage unit for compressed air Typically, the receiver is a metal,
cylindrical tank with domed ends
In addition to air storage, the receiver:
Dampens system pressure pulsations

SJCE Mech. Engg Dept Page 13

H&P PNEUMATICS MK

Removes water vapor from system air

In smaller systems, serves as the mount for the prime mover and compressor

FRL air filter removes:

Airborne dirt remaining in the atmospheric air compressed in the system
Rust and scale from the interior of the distribution lines
Liquid water that has condensed in the drop line
Atomized oil from the operating compressor.

Typical air filter uses centrifugal force and porous filter material to remove unwanted
materials from system air
Inlet passageway swirls the incoming air, creating a centrifugal force that separates air and
contaminants
Porous filter material traps other undesirable materials

Air filter:

Figure shows an air filter. Air flows thought he unit and undergoes a sudden reversal of
direction and a deflector cone swirls the air. This causes the heavier water particles present in

SJCE Mech. Engg Dept Page 14

H&P PNEUMATICS MK

the air to be flung out to the walls of the separator and collects at the bottom which can be
rained out.
Lubricator:
Figure shows a lubricator. As air enters the lubricator its velocity is increased by a venturi
ring causing local reduction in pressure in the upper chamber. The pressure differential
between the lower and upper chamber causes oil to be drawn up a riser tube emerging as a
spray to mix with air. The needle valve adjusts the pressure differential across the oil jet and
he3nce oil flow rate. The air oil mixture is forced to swirl as it leaves the central cylinder
causing excessively large oil particles to be flung out of the air stream.

Pressure Regulator:
The simplest pressure regulating device is the pressure relief valve. figure shows a pressure
relief valve where a valve is held by the spring tension on its valve seat. When the force due
to air pressure exceeds the spring tension, the valve cracks open releasing air and reducing
pressure. A relief valve is specified by it operating pressure range, span of pressure between
cracking and full flow and the flow rate.

SJCE Mech. Engg Dept Page 15

H&P PNEUMATICS MK

SJCE Mech. Engg Dept Page 16