Mechatronics Automation CH 2

Chapter (2) Pneumatic Systems
Chapter (1) Introduction to Mechatronic Automation.

Chapter (3) Sensor Technology for Sequence Control
Chapter (4) Programmable logic controllers (PLC)
Chapter (5) PLC Programming
Chapter (6) PLC (Timers, Counters & Shift Registers )
Chapter (7) Computer simulation of a programmable pneumatic positioning system
 Course Syllabus
o Pneumatics actuators, gripper technology, control valves and pneumatic circuit
representation.
o Sequential control systems.
o Sensor technology for sequence control, optical, capacitive, inductive and magnetic.
o Programmable logic controllers (PLC). Sequential control system representation,
logic analysis and PLC programming. Relay logic ladder diagram, Timers,
Counters, shift registers.
o Computer simulation of a programmable pneumatic positioning system.
 Chapter Outlines
o Pneumatics Actuators
o Control Valves
o Pneumatic Circuit Representation
o Gripper Technology
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Mechatronic Automation Dr. Ali M. Gaballa
 What is Pneumatic Systems?

Pneumatic systems use pressurized gases to transmit and control power.
 Why air?
Pneumatic systems typically use air as the fluid medium because
o Air is a safe
o Low-cost
o Readily available fluid
o It is particularly safe in environments where an electrical spark could ignite
leaks from system components.
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 Air is the only gas used as Hydraulic Fluid
o Advantages:
1. It is fire resistant
2. It is not toxic
3. It can be exhausted back into atmosphere
4. It is free
5. It is always available
o Disadvantages:
1. Air cannot be used where accurate positioning or rigid holding is required
because it is compressible.
2. It tends to be sluggish because it is compressible.
3. Air can be corrosive, since it contains oxygen and water.
4. A lubricant must be added to air to lubricate valves and actuators –air is a bad
lubricant.
5. 5.Air pressures are limited to 7 bar (application) & 10-12 bar (main lines) and
15-17 bar (storage) due to the explosion dangers involved if components such as
tanks should rupture.
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 Drawbacks
1. It is impossible to obtain precise, controlled actuator velocities with pneumatic systems,
because of the compressibility of air. Also, precise positioning control is not obtainable.
2. Where as pneumatic pressures are quite low due to compressor design limitations (less than
250 psi - 17 bar) compared to hydraulic pressures. Thus, hydraulics can be high-power
systems, where as pneumatics are confined to low-power applications.
 Applications
1. Principal applications for pneumatics include circuits where end conditions are of prime
importance (piston rod fully extended or fully retracted).
2. Pneumatic systems can be readily applied to drive rotary actuators as well.
3. Typical examples include stamping, drilling, hoisting, punching, clamping, assembling,
riveting, materials handling, and logic controlling operations.
Automobile production lines Pneumatic system of an automatic machine
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 Pneumatic in industry
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Chapter (2) Pneumatic Systems The application of pneumatic systems
 Transport system
 Vehicle door operation system
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Chapter (2) Pneumatic Systems Power Transmission Comparison
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 What is Pneumatic Systems?

Pneumatic systems use pressurized gases to transmit and control power.
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Chapter (2) Pneumatic Systems Pneumatic Systems Components
 Compressor;
o Function:
In pneumatic systems, compressors are used to compress and supply the necessary
quantities of air.
o Types:
Compressors are typically of the piston, vane, or screw type.
o Operation:
 Basically a compress or increases the pressure of a gas by reducing its volume as
described by the perfect gas laws.
 Pneumatic systems normally use a large centralized air compressor, in this way,
pressurized air can be piped from one source to various locations through out an
entire industrial plant
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 Filters:
The compressed air is piped to each circuit through an air filter to remove contaminants,
which might harm the closely fitting parts of pneumatic components such as valves and
cylinders.
 Regulator:
The air then flows through a pressure regulator. Which reduces the pressure to the desired
level for the particular circuit application.
 Lubricator:
Because air is not a good lubricant (contains about 20% oxygen), pneumatic systems
require a lubricator to inject a very fine mist of oil in to the air discharging from the
pressure regulator. This prevents wear of the closely fitting moving parts of pneumatic
components.
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 Dryer:
Free air from the atmosphere contains varying amounts of moisture. This moisture can be
harmful in that it can wash away lubricants and thus cause excessive wear and corrosion.
Hence, in some applications, air dryers are needed tore move this un desirable moisture.
 Silencers:
Since pneumatic systems exhaust directly in to the atmosphere, they are capable of gene
rating excessive noise. Therefore, mufflers are mounted on exhaust ports of air valve sand
actuators to reduce noise and prevent operating personnel from possible injury resulting not
only from exposure to noise but also from high-speed air borne particles.
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Chapter (2) Pneumatic Systems Control components in Pneumatic system
 Air control valves are used to control the pressure, flow rate, and direction of
air in pneumatic circuits.
Valves
Pressure Control Flow Control Directional Control

Valves Valves Valves
o Pressure control valves protect the system against such overpressure.

o Directional control valves are essentially used for distribution of energy in a fluid
power system.
o Fluid flow rate must be controlled in various lines of a Pneumatic circuit. For
example, the control of actuator speeds depends on flow rates. This type of control is
accomplished through the use of flow control valves.
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Chapter (2) Pneumatic Systems Valves
 Air control valves are used to control the pressure, flow rate, and direction of air
in pneumatic circuits.
 Directional control valves ensure the flow of air between air ports by opening, closing
and switching their internal connections. 14
1. Pressure Regulator
o Pneumatic pressure control valves are air line regulators that are installed at the
inlet of each separate pneumatic circuit. As such, they establish the working
pressure of the particular circuit. Sometimes air line regulators are installed
within a circuit to provide two or more different pressure levels for separate
portions of the circuit.
o The desired pressure level is established by the T-handle, which exerts a
compressive force on the spring. The spring transmits a force to the diaphragm,
which regulates the opening and closing of the control valve. This regulates the
air flow rate to establish the desired downstream pressure.
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2. Check Valve (Non-return valve)
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3. Shuttle Valve
o Shuttle valves are also known as double control or single control non-return valves.
o A shuttle valve has two air inlets ‗P1‘ and ‗P2‘ and one air outlet ‗A‘.
o When compressed air enters through ‗P1‘, the sphere will seal and block the other inlet ‗P2‘.
Air can then flow from ‗P1‘ to ‗A‘.
o When the contrary happens, the sphere will block inlet ‗P1‘, allowing air to flow from ‗P2‘ to
‗A‘ only.
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4. Flow control valve

o A flow control valve is formed by a non-return valve and a variable throttle.
o A spring-loaded disk allows free flow in one direction and an adjustable or
controlled flow in the opposite direction. Flow adjustment is performed by a
tapered brass stem that controls the flow through the cross hole in the disk.
o The adjustable knob contains a unique locking device that consists of a plastic
metering knob and thumb latch pawl.
o The valve bonnet is scribed with graduations to serve as a position indicator for
the stem.
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 Directional Control Valves

o Directional control valves ensure the flow of air between air ports by opening,
closing and switching their internal connections.
o Their classification is determined by the number of ports, the number of switching
positions, the normal position of the valve and its method of operation.
o Common types of directional control valves include 2/2, 3/2, 5/2, etc.
A, B, C : Working lines
P : Pressure (power) supply
R, S, T : Exhaust/Return
Z, Y, X : Control (Pilot) Lines
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o Directional Control Valves Classification According to :
1- Moving Element:
Rotary – Linear
Ball – Spool - Poppet
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1- Moving Element:
Rotary – Linear
Ball – Spool - Poppet
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2- Theory of Operation:
Direct
Pilot
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3- Actuating Force: Manual Mechanical Electrical Pressure
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24

25
 Directional control valve, Graphic symbols
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o 2/2 Directional control valve
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28

29

30
31

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 Directional control valve, Graphic symbols o Actuation symbols
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Chapter (2) Pneumatic Systems Pneumatics Actuators
 Actuators in pneumatic systems used to transform the fluid power into mechanical power to
achieve certain task. However, because air is the fluid medium, pressures are lower, and hence
pneumatic actuators are of lighter construction.
Pneumatics
Actuators
Linear Types Rotary air motors
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Chapter (2) Pneumatic Systems Pneumatics Actuators Linear (Push) Types
 Single-acting Pneumatic Cylinder.

o The piston uses is sealed to prevent compressed air leakage, also to provide low-
friction sealing and smooth chatter-free movement.
o The end plates use ribbed aluminum alloy to provide strength while minimizing
weight.
o Only one end plate have a connection for compressed air.
o A return spring is essential to provide the zero position after pressure release. A
guidance for cylinder rod is essential with ventilation.
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 Single-acting Pneumatic Cylinder.
Control of a single-acting pneumatic cylinder

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 Double-acting Pneumatic Cylinder.

o The piston uses is sealed to prevent compressed air leakage, also to provide low-
friction sealing and smooth chatter-free movement.
o The end plates use ribbed aluminum alloy to provide strength while minimizing
weight.
o Both end plates have a connection for compressed air.
o Self-aligning Buna-N seals provide a positive leak proof cushion.
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 Double-acting pneumatic cylinder.
Control of a double-acting pneumatic cylinder.

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Chapter (2) Pneumatic Systems Pneumatics Actuators Rotary air motors
 Rotary air motors can be utilized to provide a smooth source of power.

They are not susceptible to overload damage and can be stalled for long periods of
time without any heat problems. They can be started and stopped very quickly and
with pressure regulation and metering of flow can provide infinitely variable torque
and speed.
 Types
1. Rotary vane
2. Axial piston
3. Radial piston
4. Turbine
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1. Rotary vane air motor

Air flows through the vane motor body to end plates and then to open kidney-shaped ports,
where it enters rotor slots and pushes vanes against the housing. Air then passes into the main
motor chamber, through holes drilled in the rotor to directly pressurize exposed portions of
vanes, and turn the rotor.
Rotary vane motors normally are used in applications requiring low-to medium-power outputs.
Vane motors have axial vanes fitted into radial slots running the length of a rotor, which is
mounted eccentric with the bore of the motor's body housing. The vanes are biased to seal
against the housing interior wall by springs, cam action, or air pressure, depending on design.
The centrifugal force that develops when the rotor turns aids this sealing action. Torque develops
from pressure acting on one side of the vanes. Torque at the output shaft is proportional to the
exposed vane area, the pressure, and the moment arm (radius from the rotor centerline to the
center of the exposed vane) through which the pressure acts.
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2. Radial piston air motor

Piston air motors are used in applications requiring high power, high starting torque, and
accurate speed control at low speeds. They have either two, three, four, five, or six
cylinders arranged either axially or radially within a housing. Output torque is developed
by pressure acting on pistons that reciprocate within the cylinders.
Motors with four or more cylinders provide relatively smooth torque at a given operating
speed because power pulses overlap: two or more pistons undergo a power stroke at any
time within a revolution. Motors designed with overlapping power strokes and accurate
balancing are vibration-free at all speeds.
Power developed by a piston motor depends on the inlet pressure, the number of pistons,
and piston area, stroke, and speed.
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3. Axial piston air motor

The power pulses for these five-piston axial design motors is the same as those for the
radial piston design. At least two pistons are on the power stroke at all times, providing
even torque at all speeds.
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3. Axial piston air motor
The power pulses for these five-piston axial

design motors is the same as those for the
radial piston design. At least two pistons are on
the power stroke at all times, providing even
torque at all speeds.
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4. Turbine air motor

Turbine air motors typically were used for applications requiring very high speed and very low
starting torque.
Turbine technology offers simple, highly efficient pneumatic starters that require no lubrication
of their supply air, tolerate contaminants in the supply air, and need little maintenance
Turbine motors are relatively compact and light for their power-delivery capability. Higher gear
ratios -from 9:1 through 20:1 -provide high stall torque and versatility for a variety of engines.
Turbine horsepower is easily changed by limiting air flow through the motor.
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Chapter (2) Pneumatic Systems Pneumatic Circuit Representation
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Filter Regulator Lubricator Combined FRL Silencers
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48
 Palm button valve
 Limit valve
 Hand lever operated
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 Solenoid actuated directional control valve
 Construction of Pneumatic Cylinder
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Chapter (2) Pneumatic Systems Principles of pneumatic control
(a) Pneumatic circuit

Pneumatic control systems can be designed in the form of pneumatic circuits. A
pneumatic circuit is formed by various pneumatic components, such as cylinders,
directional control valves, flow control valves, etc. Pneumatic circuits have the
following functions:
1. To control the injection and release of compressed air in the cylinders.
2. To use one valve to control another valve.
(b) Pneumatic circuit diagram
A pneumatic circuit diagram uses pneumatic symbols to describe its design. Some
basic rules must be followed when drawing pneumatic diagrams.
(i) Basic rules
1. A pneumatic circuit diagram represents the circuit in static form and assumes
there is no supply of pressure. The placement of the pneumatic components on
the circuit also follows this assumption.
2. The pneumatic symbol of a directional control valve is formed by one or more
squares. The inlet and exhaust are drawn underneath the square, while the outlet
is drawn on the top. Each function of the valve (the position of the valve) shall be
represented by a square. If there are two or more functions, the squares should
be arranged horizontally .
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(i) Basic rules
3. Arrows "↓↖" are used to indicate the flow direction of air current. If the external
port is not connected to the internal parts, the symbol ―┬‖ is used. The symbol
―⊙‖ underneath the square represents the air input, while the symbol ―▽‖
represents the exhaust.
4. The pneumatic symbols of operational components should be drawn on the outside
of the squares. They can be divided into two classes: mechanical and manual
3/2 directional control valve
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(ii) Basic principles
Figure below shows some of the basic principles of drawing pneumatic circuit
diagrams, the numbers in the diagram correspond to the following points:
1. When the manual switch is not operated, the

spring will restore the valve to its original
position.
2. From the position of the spring, one can
deduce that the block is operating. The other
block will not operate until the switch is
pushed.
3. Air pressure exists along this line because it is
connected to the source of compressed air.
4. As this cylinder cavity and piston rod are
under the influence of pressure, the piston
rod is in its restored position.
5. The rear cylinder cavity and this line are
connected to the exhaust, where air is
released.

(iii) The setting of circuit diagrams
When drawing a complete circuit diagram, one should place the pneumatic components on
different levels and positions, so the relations between the components can be expressed
clearly. This is called the setting of circuit diagrams. A circuit diagram is usually divided into
three levels: power level, logic level and signal input level
Flow control valve
Shuttle Valve
 The basic rules of circuit diagram setting are as follows:
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Chapter (2) Pneumatic Systems Different kinds of basic circuits
 OR Function  AND Function
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Chapter (2) Pneumatic Systems The application of pneumatic systems
 Transport system
 Vehicle door operation system
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Chapter (2) Pneumatic Systems Symbols of Pneumatic Supply Components
Circuit diagram of a simple pneumatic system

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Pressure Control Valves
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Flow Control Valves
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Symbols for Directional Control Valves
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Pneumatics Actuators: Linear Types Rotary air motors
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Control of Single Acting Cylinder Motion

The piston of a single-acting cylinder is to travel out when a button is operated and return at
once to its end position when the button is released.
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Control of Double Acting Cylinder Motion
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Indirect Control of a S Acting Cylinder
The piston of a large-volume single acting cylinder (large diameter, large stroke length) is to
travel out after actuating a valve and return to its end position after the valve has been
released.
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Indirect Control of a D Acting Cylinder

A double acting cylinder is to be controlled by two valves 2, and 3 such that the piston travels
out when Valve 2 is actuated and remains FIXED in the forward end position after 2 has been
released until the reverse signal for the return movement is input through 3.
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Chapter (2) Pneumatic Systems Case Studies: Basic Pneumatic Circuits
Manual control of a single-acting cylinder
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Unidirectional speed control of a single-acting cylinder
Throttle Valve (TC)

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Bidirectional speed control of a single-acting cylinder
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OR control of a single-acting cylinder.

 Initially, the cylinder is fully retracted, with both push buttons PB1 and PB2 released (see Fig. a).
The system is equipped with an OR element. The cylinder can be operated if any of the two push
buttons, PB1 or PB2, are depressed—positions (b) and (c)
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AND control of a single-acting cylinder

 To out-stroke the cylinder, both directional control valves must be operated (see Fig. a). This
provides an AND logic function. The cylinder retracts if any or both of the two directional
control valves are released (see Fig. b, c, and d).
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Logic NOT control.
 The logic NOT function is provided by a normally open directional control valve (see
{a}). Thus, the cylinder extends if the DCV is NOT operated. The cylinder retracts by
switching the DCV (see{b}).
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Chapter (2) Pneumatic Systems

Chapter (1) Introduction to Mechatronic Automation.

 What is Pneumatic Systems?

 Air is the only gas used as Hydraulic Fluid

Automobile production lines Pneumatic system of an automatic machine

 Vehicle door operation system

 What is Pneumatic Systems?

Pressure Control Flow Control Directional Control

o Pressure control valves protect the system against such overpressure.

2. Check Valve (Non-return valve)

4. Flow control valve

 Directional Control Valves

 Directional Control Valves

 Directional Control Valves

 Directional Control Valves

 Directional Control Valves

 Directional Control Valves

 Directional Control Valves

 Directional control valve, Graphic symbols

 Directional control valve, Graphic symbols

o 2/2 Directional control valve

 Directional control valve, Graphic symbols

 Directional control valve, Graphic symbols

 Directional control valve, Graphic symbols

o 5/2 Directional control valve

 Directional control valve, Graphic symbols

o 4/2 Directional control valve

 Directional control valve, Graphic symbols

 Directional control valve, Graphic symbols

 Directional control valve, Graphic symbols o Actuation symbols

Linear Types Rotary air motors

 Single-acting Pneumatic Cylinder.

 Single-acting Pneumatic Cylinder.

Control of a single-acting pneumatic cylinder

 Double-acting Pneumatic Cylinder.

 Double-acting pneumatic cylinder.

Control of a double-acting pneumatic cylinder.

 Rotary air motors can be utilized to provide a smooth source of power.

1. Rotary vane air motor

2. Radial piston air motor

3. Axial piston air motor

3. Axial piston air motor

The power pulses for these five-piston axial

4. Turbine air motor

Filter Regulator Lubricator Combined FRL Silencers

 Palm button valve

 Hand lever operated

 Solenoid actuated directional control valve

 Construction of Pneumatic Cylinder

(a) Pneumatic circuit

(b) Pneumatic circuit diagram

3/2 directional control valve

(b) Pneumatic circuit diagram

1. When the manual switch is not operated, the

(b) Pneumatic circuit diagram

Flow control valve

 The basic rules of circuit diagram setting are as follows: