Chapter 3 : Automation Tools and Assembly System

3.1 Hardware Components for Automation & Process

Control
•Actuators
•Sensors
•Analog to Digital Converters
•Digital to Analog Converters
•Input/Output Device for Discrete Data

ENT471 Automation
 Actuators

•Hardware devices that convert a controller command signal

into a change in a physical parameter

•The change is usually mechanical (e.g., position or velocity)

•An actuator is a transducer because it changes one type of

physical quantity into some alternative form

•An actuator is usually activated by a low-level command

signal, so an amplifier may be required to provide sufficient
power to drive the actuator

ENT471 Automation
 Actuators

Practically every industrial process requires objects

to be moved, manipulated, held, or subjected to some type of
force.

•The three most commonly employed methods for

producing the required forces/motions are:

Air – Pneumatics

Liquids – Hydraulics

Electrical – motors, solenoids

ENT471 Automation
Actuators
A brief system comparison:
The task considered is how to lift a load by a distance
of about 500 mm. Such tasks are common in
manufacturing industries.
Pneumatics

ENT471 Automation
Actuators

Hydraulics

ENT471 Automation
Actuators
Electrical Actuators - motor

ENT471 Automation
 Actuators
DRIVES AND CONTROL ENGINEERING FOR ACTUATORS
Energy (Medium) Control Drive Actuator Type

Electrical Contactor and relay control Power contactor DC motor

-electrical current Digital and analog control Thyristors AC motor
•Wired program Stepper motor
•Freely programmable Solenoid
system
Pneumatics Digital control Directional Motors
Conventional valve tech. Valve Cylinders
-compressed air
from compressors Solenoid Flow control Tools-gripper
Pneumatic logic system Valves
Programmable module
Hydraulics Mechanical driven Directional Motors
Manual driven Valve Cylinders
-hydraulic fluids
using pump Solenoid Flow control
Valves
Special Valve
 Actuators

Comparison Between Electrical, Pneumatic & Hydraulic Actuator and System

Parameter Hydraulic Electrical Pneumatic

Transmission Limited and very Very fast overlarge Limited and slow
slow distance

Energy cost high low very high

Generation of linear Very simple Complex and costly Very simple

motion
Linear speed Simple & accurate complex simple

Force Very high high limited

Generation of rotary simple complex simple

motion
Connection complex simple Very simple

Explosive proof partial no yes

Efficiency good good poor

 Pneumatics

Introductions to Pneumatic System and Applications

•Properties & Applications area of pneumatics
•Pneumatic Drives and actuators
•Directional Control Valve, Pressure Control Valve and Logic
Valve
•Sequential Control
•Example of pneumatic application in automated machine

ENT471 Automation
 Pneumatics

Properties & Applications area of pneumatics

ADVANTAGES OF PNEUMATICS
Pneumatics is used in preference to hydraulics for the following reasons.
1. Easily connected to an air supply and needs no separate power pack.
2. The operation of actuators is fast.
3. No return piping is required; the air is vented to atmosphere.
4. Clean medium with no mess when it leaks.
5. No fire hazard as with oil.

Pneumatics is used in preference to electrics for the following reasons.

1. Will not start a fire through electric fault (Intrinsically safe).
2. Easily to generate linear motion
3. Air motors are safe when over loaded and does not overheat.
4. Safer for operators (no risk of electrocution).

ENT471 Automation
 Pneumatics

2. COMPONENT CLASSIFICATION

Pneumatic circuit elements are classed into four primary groups. These are
1. AIR SUPPLY AND CONDITIONING ELEMENTS such as
•Compressor
•Receiver
•Pressure regulator,
•Filter
•Dryer
•Lubricator

2. INPUT ELEMENTS (electrical or pneumatic) such as

•On/off devices (switches)
•Position sensors
•Trip valves
•Air jet sensors
•Note many pneumatic sensing and switching devices are directional control valves
such as a 3/2 plunger or roller operated valve for detecting a cylinder position.

ENT471 Automation
 Pneumatics

3. PROCESSING ELEMENTS such as

•Logic valves (And Or and so on)
•Time delay valves
•Pressure switches
•Directional control valves of many types.

4. CONTROL ELEMENTS such as

•Directional control valves
•Flow control valve

5. POWER OR ACTUATING DEVICES such as

•Cylinders
•Motors
•Semi-rotary actuators

ENT471 Automation
 Pneumatics

Power Components
-double acting cylinder
Control element
-5/2 way directional valve
(pilot actuated)
-Throttle valve
Processing element
-OR & AND Valve (Logic)
Input element
-3/2 way valve NC (push
button actuated)
-3/2 way valve NC (roller
actuated)
Supply Element
-Compressor
-FRL Unit
ENT471 Automation
Pneumatics
Identify Power, Control, Processing and Input Element

Automation Studio Demo

ENT471 Automation
 Pneumatics
Pneumatic Drives and actuators

Pneumatic Cylinder
Single acting cylinder
Double acting cylinder
Rod less cylinder

Pneumatic motor
-1 direction
-2 direction

Tools
Suction cup
Gripper Pneumatic Actuator
Air Gun
ENT471 Automation
 Pneumatics

Pneumatic Cylinder Properties

Ap = D².π / 4 Fv = P.Ap Vv = Ap.L

Ar = (D² - d²)π / 4 Fr = P.Ar Vr = Ar.L

ENT471 Automation
Pneumatics

Determine cylinder forward stroke & return stroke force

• A double acting cylinder is driven by compress air and had
below property:
Piston diameter, D = 63mm
Rod diameter, d = 20mm
Stroke, L = 300 mm
Operating pressure = 6 bar
Calculate: 1) forward stroke Fv and return Fr for the cylinder.
2) volume for double stroke
Answer :
• Piston Area, Ap & Annulus area,Ar
• Forward stroke, Fv
• Return stroke, Fr
• Double stroke, Vv + Vr
ENT471 Automation
Pneumatics

Determine piston diameter

• A double acting cylinder must lift a 48 Kg load vertically if
acceleration force, a is 10ms-2 and cylinder efficiency is
90%.
• Calculate piston diameter would be needed with maximum
working pressure of 5 bar?
Answer:
1) Gravitational Force, Fg
2) Acceleration Force, Fa
3) Total Force, Ft
4) Necessary force
5) Piston area and piston diameter

ENT471 Automation
 Pneumatics
Directional Control Valve

Configuration and construction

• Directional valve are devices which influence the path taken by air stream.
• Characterized by:
1. Number of control connections or way
2. Number of switching position
3. Method of actuation
Example: 3/2 way Normally Open, internal pilot and spring actuated

ENT471 Automation
 Pneumatics
Directional Control Valve

Construction principal is important factor to determine:

- Service life, switching time, type of actuation, connection method and size
Design categorized as follows:
• Poppet valve (ball seat valve, disc seat valve)
• Slide valve (spool valve, longitudinal flat slide valve, plate slide valve)

ENT471 Automation
 Pneumatics
Directional Control Valve
Method of actuation can be :
•Manually - push button, lever operated, detend lever operated, foot pedal
•Mechanical – plunger, roller idle return roller, spring return
•Pneumatic – external pilot, internal pilot
•Electrical – single solenoid, double solenoid
•Combined – solenoid with internal pilot

ENT471 Automation
 Pneumatics
Directional Control Valve
2/2 way valve
-Two port and two position (open/closed)
-Rarely used in pneumatic except for on/off valve
3/2 way valve
-Three port and two position
-The valve connect the output signal 2 to exhaust 3 thus to atmosphere in initial position
-A spring force a ball against the valve seat preventing the compressed air from flowing from
the air connection 1 to the working line 2.
- used to control single acting cylinder

ENT471 Automation
 Pneumatics
Directional Control Valve
5/2 way valve
-Have 5 port and 2 positions
-Used to control double acting cylinder for extend and retract position

5/3 way valve

-Have 5 port and 3 positions
-Used to control double acting cylinder for extend/retract position and can stop at any point
stroke range.

ENT471 Automation
 Pneumatics
Flow and Pressure Control Valve
Non return valve
Valve which preferentially stop flow in one direction and permit in the opposite
direction
•Check Valve – stop the flow completely in one direction
•Dual pressure valve (AND valve) – compressed air only flow through the valve only
if signals is applied to both inlets
•Shuttle valve (OR Valve) – compressed air will flow through when signal is applied
at any inlet

ENT471 Automation
 Pneumatics
Flow and Pressure Control Valve
Flow control valve
Valve which influence the volumetric flow of the compressed air
•Throttle valve – used for speed control of cylinder
•Choke valve (one way flow control) – combination of throttle valve and check valve.
The flow is throttle in one direction only. Can be supply air throttle or exhaust air
throttle.

ENT471 Automation
 Pneumatics
Flow and Pressure Control Valve
Pressure control valve
Valve which predominantly influence the pressure or are controlled by the
magnitude of the pressure.
•Pressure regulator – maintain constant pressure even with fluctuating supply. Input
pressure must be greater than required output pressure
•Pressure limiting valve – mainly used as safety valves. Prevent the maximum
permissible pressure being exceeded. If maximum pressure been reached the valve
outlet opened and excess air pressure exhaust to atmosphere.
•Pressure sequence valve – are installed in pneumatic controls where a specific
pressure is required for switching operation (pressure dependent controls)

ENT471 Automation
 Pneumatics
Sequence Control
Displacement step-diagram represent the desired motion of multiple actuators. The
special conditions for the start of the sequence must be defined.
Example : Co-coordinated motion

ENT471 Automation
 Pneumatics
Sequence Control

Sequential Function Chart (SFC) - Graphic representation using basic SFC

components used to represent an automatism or sequence of the actuator and also
can be represent the sequence of the process
Example: Drilling machine

ENT471 Automation
 Pneumatics
Example of pneumatic application in automated machine
Some industrial application employing
pneumatics
•General methods of material handling
-Clamping, shifting positioning, orienting
and branching of material flow
General applications:
-Packaging, filling, driving of axes, door
or chute control, sorting of part, stamping
of components .etc..
Pneumatics is used in carrying out
machining and working operations
- drilling, turning milling, forming, gripper
and vacuum for pick and place etc..

ENT471 Automation
 Electro-Pneumatics

2.3 Introductions to Electro-Pneumatic System and Applications

Contact Switch, Electromagnetic Contactor & Relays
Solenoid Valve and electro-pneumatics sensor
Example of electro-pneumatic circuit & application in automated machine
Electro-pneumatics and PLC interface for sequential control

Contact Switch
-Can be Normally Open (NO) and Normally Closed (NC)
-The switch can be push button, proximity switch, limit switch and contact from relay.

ENT471 Automation
 Electro-Pneumatics

Relay
-The relay is mechanical switch and the contacts a moved by a solenoid.

Solenoid Valve
- Solenoid valve convert electrical energy to electromagnetic filed that draws the
armature or plunger in the valve to open or close compressed air inlet and switch the
valve position.

ENT471 Automation
 Pneumatics
Electro-Pneumatic
Electro-pneumatic sensor
-To control the cylinder movement,
sensor are fitted to provide a switching
voltage at operated position.

Mechanically operated switch or

micro switch

Magnetically operated reed switch

Cylinder position also can be monitor

using proximity sensor using photo
sensor (transmitter and receiver)

ENT471 Automation
 Electro-Pneumatics

Example of electro-pneumatic circuit & application in automated machine

Problem : Change the circuit using 5/2 way solenoid actuated with spring return.
Develop the electrical circuit to control same sequence
ENT471 Automation
 Electro-Pneumatics
Electro-Pneumatic

Product transfer on two level conveyors.

Step diagram and SFC?

ENT471 Automation
 Electro-Pneumatics

Electro-pneumatics and PLC interface for sequential control

ENT471 Automation
 Hydraulic

Introductions to Hydraulic System and Applications

Properties & Applications area of hydraulic

Hydraulic widely used throughout industry and throughout the world. Example:
•Ram for extrusion press
•Machine tools
•Stamping machine
•Aero plane control
•Excavators
•Braking system on car

Hydraulic usually used for precise control of large forces. Example: rudder control on
aero plane)

ENT471 Automation
 HYDRAULICS

Definition
Hydraulics is the science
of transmitting force and/or
motion through the medium
of a confined liquid.

Power is transmitted by
pushing on a confined liquid
 Hydraulic
Hydraulic Components
•Hydraulic Tank (fluid reservoir)
All hydraulic systems must have some form of a
reservoir to hold the fluid in the system. Most
systems have vented tanks
•Hydraulic Pump
A pump displaces fluid which creates flow.
There are fixed displacement pumps and
variable displacement pumps.
•Pressure Relief Valve
All hydraulic systems must have a pressure
relief valve in line with the pump. The pressure
relief will drain into the tank. If the fluid can't go
anywhere the pump will stall, and damage to
the pump and motor.

ENT471 Automation
 Hydraulic
Directional Control Valve
2/2 way valve.

4/2 way valve

4/3 way valve

Example of hydraulic circuit using automation studio using different valve

ENT471 Automation
Hydraulic

ENT471 Automation
 Hydraulic

Example of hydraulic application in automated machine

ENT471 Automation
 Hydraulic
Pneumatic Vs Hydraulic

ENT471 Automation
 Automation Tools and Assembly System
Introductions to Hydraulic System and Applications
Pneumatic Vs Hydraulic
 Hydraulic

Pneumatic Vs Hydraulic

ENT471 Automation
 Hydraulic

Pneumatic Vs Hydraulic

ENT471 Automation
 Hydraulic

Hydraulic Calculation

ENT471 Automation
Hydraulic

ENT471 Automation
Hydraulic

ENT471 Automation
 Hydraulic

Example:

A single-acting hydraulic cylinder with spring return has an inside diameter of 88 mm.
Its application is to push pallets off of a conveyor into a storage area. The
hydraulic power source can generate up to 3.2 MPa of pressure at a flow rate, Q
of 175,000 mm3/sec to drive the piston. Determine

(a) the maximum possible speed of the piston

(b) the maximum force that can be applied by the apparatus.

Solution:
Area of cylinder A = [(88)² π] / 4 = 6082 mm2

(a) Speed, V = Q/A = (175,000 mm3/sec) / 6082 mm2 = 28.77 mm/sec

(b) F = pA = (3.2 N/mm2)(6082) = 19,462 N

ENT471 Automation
 Hydraulic

Exercise:

1) A double acting cylinder with a single rod must produce a force of 80kN and move
out velocity of 3mm/s on the out stroke. The operating pressure is 100 Bar.
Calculate the bore diameter required and flow rate of the oil.
Answer : 101 mm and 24 cm³/s

2) A double-acting hydraulic cylinder has an inside diameter = 75 mm. The piston

rod has a diameter = 14 mm. The hydraulic power source can generate up to 5.0
MPa of pressure at a flow rate of 200,000 mm3/sec to drive the piston.

(a)What are the maximum possible velocity of the piston and the maximum force
that can be applied in the forward stroke?
(b) What are the maximum possible velocity of the piston and the maximum force
that can be applied in the reverse stroke?

(a) Forward stroke v = 45.3 mm/sec , F = 5(4418) = 22,090 N

(b) Reverse stroke v = 46.9 mm/sec , F = 5(4264) = 21,320 N
ENT471 Automation