MECH610/PNEUMATICS & ELECTRO-PNEUMATICS

Module 3 (LEC) – Actuators and Processing Elements

Development of Direct and Indirect Actuator Circuits

Learning Outcomes:
At the end of this module, students are expected to:
C1. Demonstrate critical knowledge and understanding of core pneumatic and/or
electro-pneumatic theories and concepts.
C2. Critically evaluate problems and provide appropriate solutions to real-life
production problems involving pneumatic and/or electro-pneumatic systems.
C3. Apply pneumatic and/or electro-pneumatic standards and design to produce
solution that meet given mechatronic system specification.

Specifically,
 Output Devices
 Directional Control Valves
 Direct and Indirect Actuations

Introduction
Power components or actuators are output devices that convert a type of certain
energy into useful work. Controlled by the control system, actuator responds to the
control signals via the control element. Other types of output devices are used to
indicate the status of the control system or actuators.

Pneumatic actuators can be categorized into linear and rotary:

 Linear Motion
o Single-acting Cylinders
o Double-acting Cylinders
 Rotary Motion
o Air Motor

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 o Rotary Cylinders
o Rotary Actuators

SINGLE-ACTING CYLINDERS
A single-acting cylinder has only one port which is at the rear end of the piston where
compressed air is applied. The other side is open to atmosphere. The cylinder can
produce work in only one direction. The piston’s return movement is effected by a built-
in-spring or by the application of an external force. Under no load conditions, the spring
force of the built-in spring is designed to return the piston to its start position with a
reasonably high speed

Figure1. Parts of Single-Acting Cylinder

The single-acting cylinder has a single piston seal which is fitted on the air supply side.
Sealing is by a flexible material that is embedded in a metal or plastic piston
(Perbunan). During motion, the sealing edges slide over the cylinder bearing surface.
Available single-acting cylinders has stroke lengths up to approximately 80mm. Short
stroke length cylinders are used for the following types of application:
 Transferring
 Branching
 Allocating
 Clamping
 Ejecting

DOUBLE-ACTING CYLINDERS
Double-acting cylinder has two ports that are used alternatively as supply and exhaust
ports that are able to carry out work in both directions of motion. Force in the forward
stroke is greater than the return stroke as the effective piston surface is reduced on the
piston rod side.

Figure2. Parts of Double-Acting Cylinder

Types of Double-acting Cylinder based on Cylinder’s design
 Figure3. Cylinder with end position cushioning

For the prevention of shock due to stopping loads at the end of the piston stroke,
cushion devices are used. Cushions maybe applied at either end or both ends. They
operate on the principle that as the cylinder piston approaches at the end of stroke
exhaust pressure is forced to go through an adjustable needle valve that is set to control
the escaping pressure at the given rate. This allows the deceleration of the piston during
extension and/or retraction.

Figure4. Rodless Cylinder

Rodless cylinders are developed to overcome the limitation in space by removing the
piston rod that extends outside the cylinder body. Instead, the internal piston is
connected to an external carriage using a mechanical or magnetic coupling system.
 Figure5. Tandem Cylinder

Tandem cylinders are designed by joining the features of two double-acting cylinders to
form a single unit. This design almost doubles the force on the piston rod which is
suitable for applications where bigger force is required.

Figure6.Cylinders with through piston rod

Both sides of this cylinder has a through piston rod on both sides that has identical force
in both directions of movement.
 Figure7.Multi-position Cylinders

Two or more double-acting cylinders are interconnected where every cylinder extends
when pressure is applied (e.g. four positions are obtained by interconnecting two
cylinders as shown in the figure above).

Figure8.Impact Cylinders

This cylinder offers piston speed between 7.5 m/s and 10 m/s over short forming
distances.
 Figure9. Rotary Cylinders
This double-acting cylinder has a gear wheel that is driven by the piston rod that
resulted to rotary movement which varies from 450, 900, 1800, 2700 and 3600.

Figure10. Rotary Vane Actuators

Rotary actuators are used to achieve angular motion that produces high torque output.
Standard rotations are 900, 1800 and 2700. Rotary actuators are mainly available in
three designs: vane type, rack and pinion type and helix spine.

Valve is a device controlling the direction, pressure and rate of flow of air delivered by a
compressor to the actuator. Valves are classified into four principal groups according to
their functions:
 Directional control valves
  Non-return valves
 Flow control valves
 Pressure control valves

DIRECTIONAL CONTROL VALVE (DCV)

DCVs re used to control the direction of air flow in the pneumatic circuit from input port
to output ports by generating, relieving and redirecting the air signals. Types of
directional control valves:
1. Based on construction element used
 Ball Seat
 Disc Seat
 Diaphragm
2. Based on the number of ports
 Two-way
 Three-way
 Four-way
3. Based on the methods of actuation
 Mechanical
 Electrical
 Pneumatic

As per the ISO 5599, ports are designated using a number system for pneumatic
valves. DCVs are described by the number of port connections, number of position and
flow path.
 Figure11. Ports and Positions of DCVs
The symbols for the methods of actuation for DCVs are detailed in DIN ISO 1219 where
method of initial actuation and also method of return actuation are considered.
Figure12. Methods of Actuation
POPPET DIRECTIONAL CONTROL VALVES
In a poppet valve, discs, cones, plates or balls are used to control the flow of air inside
the valve. If the push button is pressed, the ball will lift off from its seat and allows the
air to flow from port P to port A. When the push button is released spring force and air
pressure keep the ball back and closes the air flow.

SLIDE DIRECTIONAL CONTROL VALVES

In slide valves, the individual connections are linked together or closed by means of
spools, flat slide or plate slide valves.

2/2-way Valve
The 2/2-way valve has two ports and two positions (open, closed). It is rarely used
except an on-off valve, since its only function is to enable signal flow through and
cannot release the air to atmosphere once in the closed position in contrast to the 3/2
way valve. The 2/2 way valve is normally of the ball seat construction. This valve can be
operated either manually, mechanically or pneumatically.

3/2-way Valve
The 3/2-way valve is a signal generating valve, with the characteristic that a signal on
the output side of the valve can be generated and also cancelled. The 3/2-way valve
has three ports and two positions. The addition of the exhaust port 3 enables the signal
generated via the passage through the 3/2 way valve to be cancelled. The valve
connects the output signal 2 to exhaust 3 and this to atmosphere in the initial position. A
spring forces a ball against the valve seat preventing the compressed air from flowing
from the air connection 1 to the working line 2.

3/2 way valve can be normally closed or normally open. In normally closed 3/2-way
valve, the valve is at rest with port 1 blocked and the cylinder exhausted to atmosphere
via the connection port 2 to 3. The actuation of the push button diverts the supply (port
1) to the output port 2 and the cylinder extends. When the push button is released the
valve returns to its initial position by spring where the pressure that causes the cylinder
to extend is release thus causing the cylinder to retract.

In normally open valve, compressed air supplied in port 1 is directly connected to output
port 2 that causes direct extension of the cylinder. When the push button is actuated,
the air in port 1 is blocked by the stem seat and then the disc is pushed off its seat to
exhaust the air in post 2 t atmosphere via port 3. When the push button is released, the
plunger returned to its initial position via the return spring and again post 3 is blocked
and the air is supplied from 1 to 2.

Roller Lever Valve

The roller level valve with idle return only switches if the movement of the trip cam on
the roller level is in a certain direction. The valve is used as a limit switch for the position
sensing of the extended and retracted piston rod. Similarly, this type of valve can be
used either in the normally open or normally closed position. In the case of the normally
open position, only ports 1 and 3 need to be inversely connected to the normally closed
position. The head of the valve with roller lever actuator can be repositioned by 1800.

5/2-way Valve
The 5/2-way valve has five ports and two positions. The 5/2-way valve is used primarily
as a control element for the control cylinders. Initially, compressed air is supplied in port
1 that id directly connected to output port 2 while output port 4 is connected to exhaust
port 5 with exhaust port 3 is blocked.

For single piloted 5/2-way valve with spring return, pilot port 14 is actuated, plunger
moves the valve to switched position where air supplied in port 1 is connected to output
port 4 and pressure in output port 2 is exhausted to port 3 while port 5 is being blocked.
Once signal in the pilot port is removed, the plunger returns to its initial position via the
spring.
For 5/2-way double piloted valve (memory valve), a pneumatic signal at pilot port 14
causes the spool to switch over as discussed previously. The valve remains in that
position even if the signal at port 14 is removed. If the signal is applied at pilot port 12,
the spool switches. In this position, paths are from 1 to 2 and from 4 to 5 are open and
exhaust port 3 is blocked. The valve remains in this position even if the signal at port 12
is removed. Hence, a 5/2-way double piloted valve has a memory function.

References and Supplementary Materials:

Jagadeesha T., Hydraulics and Pnuematics. 2015
P. Croser and F. Ebel, Pneumatics (FESTO). 2002

Online Supplementary Reading Materials:

http://www.academia.edu/Documents/in/PNEUMATIC_SYSTEMS
https://resources.hkedcity.net/res_files/201101/20110128101153_259037.pdf

Online Instructional Videos:

https://www.youtube.com/watch?v=eteFWRt8qDY
https://www.youtube.com/watch?v=f5-1RvkMIjs