FPS Module 4

SUBJECT: FLUID POWER SYSTEMS (17ME72)
MODULE 4: PNEUMATIC POWER SYSTEMS
INTRODUCTION TO PNEUMATIC SYSTEMS:
A system that uses the compressed air and transmits the energy contained in it to do
mechanical work is called a pneumatic system.
Its basic elements are:
- Compressor which raises air pressure to the required level
- Receiver tank to store the compressed air at required pressure
- Control valves for regulating and controlling the flow, direction and pressure of
compressed air.
- Actuators like Cylinders and Air motors which are used to perform the useful work
for which the system is designed.
- Auxiliary devices like Filter, Regulator and Lubricator
Advantages of Pneumatic systems:
1. The working medium is air which is widely available, compressible and easily
transportable.
2. The fire-proof characteristic of air makes the pneumatic systems safe from explosions.
3. The pneumatic elements used are simple in construction and cheaper compared to
those of hydraulic systems. Moreover, maintenance cost is low because the working
medium is air unlike oil used in hydraulic system.
4. High degree of controllability of pressure, speed and force exists.
5. Pneumatic systems can operate in hazardous environments wherein hydraulic,
electrical or steam power systems cannot operate.
Limitations of Pneumatic systems:
1. Suitable only for low pressure and hence low force applications.
2. Generation of the compressed air is expensive compared to electricity.
3. Less precise. It is not possible to achieve uniform speed due to compressibility of air.
4. Rigidity of the system is poor.
5. Vulnerable to dirt and contamination.
NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU
Applications of Pneumatic systems:

1. Aircraft manufacturing 10. Machine tool manufacturing
2. Chemical plants 11. Material conveying
3. Cement plants 12. Metal forming
4. Coal mines 13. Oil refineries
5. Cotton mills 14. Paper mills
6. Dairies 15. Printing
7. Distilleries 16. Space exploration
8. Foundries 17. Steel mills
9. Forge shops 18. Vehicle manufacturing
Characteristics of compressed air:

1. Compressed air can be stored.
2. Compressed air is easily conveyed in pipelines even over longer distances.
3. Compressed air need not be returned. It can be vented to atmosphere after it has
performed work.
4. Compressed air is insensitive to temperature fluctuation. This ensures reliable
operation even in extreme temperature conditions.
5. Compressed air is clean. This is especially important in food, pharmaceutical, textile,
beverage industries.
6. Compressed air requires good conditioning in order to remove the dust or moisture
present in it.
7. Compressed air due to its low conductivity cannot dissipate heat as much as
hydraulic fluid.
Choice of working medium and system:

The choice of medium depends on the application. Some of the general, broad rules followed
in the selection of a working medium are listed below.
 When the system requirement is high speed, medium pressure (usually 6 to 8 bar) and
less accuracy of position, then pneumatic system is preferred.
 If the system requirement is high pressure and high precision, a fluid system with oil
is good. When the power requirement is high like in forging presses, sheet metal
press, it is impossible to use air system. Oil hydraulics is the only choice

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 Air is used where quick response of actuator is required.

 If temperature variation range in the system is large, then use of air system may run
into condensation problems and oil is preferred.
 If the application requires only a medium pressure and high positional accuracy is
required then hydro –pneumatic system is preferred
 Air is non-explosive, it is preferred where fire/electric hazard are expected. Oil
systems are more prone to fire and electrical hazards and are not recommended in
such applications.
Structure of Pneumatic control system:

The important components of a pneumatic system are shown in fig.1
1. Air filters: These are used to filter out the contaminants from the air.
2. Compressor: Compressed air is generated by using air compressors. Air compressors
are either diesel or electrically operated. Based on the requirement of compressed air,
suitable capacity compressors may be used.
3. Air cooler: During compression operation, air temperature increases. Therefore
coolers are used to reduce the temperature of the compressed air.
4. Dryer: The water vapour or moisture in the air is separated from the air by using a
dryer.
5. Control Valves: Control valves are used to regulate, control and monitor for control
of direction flow, pressure etc.
6. Air Actuator: Air cylinders and motors are used to obtain the required movements of
mechanical elements of pneumatic system.
7. Electric Motor: Transforms electrical energy into mechanical energy. It is used to
drive the compressor.
8. Receiver tank: The compressed air coming from the compressor is stored in the air
receiver.

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Figure 1
Working:
The electric motor drives the compressor. The compressor creates suction pressure and
draws in air through a filter. The filter traps suspended particles like dirt, dust, etc. and allows
clean air into the compressor. The compressor compresses the filtered air to higher pressure
and this again depends on its capacity. Due to compression, the air gets heated up. The hot air
is passed through an air treatment unit consisting of a cooler and a separator. Here, the air
cools and its moisture content gets removed. The treated high pressure air is stored in a
receiver. In case the pressure of stored air in the reservoir exceeds a predetermined value, the
pressure switch does the sensing and cuts the motor supply to the compressor. The high
pressure air from the receiver is subjected to secondary treatment. It is used to run the
actuator through the control valve.
COMPRESSOR:
The compressor that is used in a pneumatic control system can be of Positive displacement
type or Dynamic displacement type.
1. Positive displacement compressors:
These work on the principle of increasing the pressure of a definite volume of air by
reducing that volume in an enclosed chamber.
(a) Reciprocating type: The compressing element undergoes reciprocating motion.

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i) Single acting compressor: The compression takes place in the space on

one side of the piston with one compression stroke for each revolution of
the crankshaft.
ii) Double acting compressor: The compression takes place on both faces of
the piston giving two compression strokes for each revolution of the
crankshaft.
(b) Rotary type: The compressing element undergoes rotary motion.
2. Dynamic displacement compressors:
These work on the principle of increasing the pressure of air by acceleration due to
rapidly rotating elements such as rotor blades.
FLUID CONDITIONER:
For satisfactory operation of the pneumatic system the compressed air needs to be cleaned
and dried. Atmospheric air is contaminated with dust, smoke and is humid. These particles
can cause wear of the system components and presence of moisture may cause corrosion.
Hence it is essential to treat the air to get rid of these impurities. The air treatment can be
divided into three stages as shown in fig 2.
Figure 2
In the first stage, the large sized particles are prevented from entering the compressor by an
intake filter. The air leaving the compressor may be humid and may be at high temperature.
The air from the compressor is treated in the second stage. In this stage temperature of the
compressed air is lowered using a cooler and the air is dried using a dryer. Also an inline
filter is provided to remove any contaminant particles present. This treatment is called
primary air treatment. In the third stage which is the secondary air treatment process, further
filtering is carried out. A lubricator introduces a fine mist of oil into the compressed air. This
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will help in lubrication of the moving components of the system to which the compressed air
will be applied.
Inlet filter:
This can be dry or wet filters. Dry filters use disposable cartridges. The cartridges are
replaced during servicing. In the wet filter, the incoming air is passed through an oil bath and
then through a fine wire mesh filter. Dirt particles cling to the oil drops during bubbling and
are removed by wire mesh as they pass through it. The wet filters are cleaned using detergent
solution.
Cooler:
A cooler is a type of heat exchanger. There are two types of coolers commonly employed viz.
air cooled and water cooled. In the air cooled type, ambient air is used to cool the high
temperature compressed air, whereas in the water cooled type, water is used as cooling
medium. These are counter flow type coolers where the cooling medium flows in the
direction opposite to the compressed air. During cooling, the water vapour present will
condense which can be drained away later.
Main line filter:
This filter is used to remove the water vapours or solid contaminants present in the pneumatic
systems main line. It is basically an air filter and water trap.
Figure 3

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The schematic of the filter is shown in fig.3. The filter cartridge is made of sintered brass.
The thickness of sintered cartridge provides random zigzag passage for the air to flow-in
which helps in arresting the solid particles. The air entering the filter swirls around due to the
deflector cone. The centrifugal action causes the large contaminants and water vapour to be
flung out, which hit the glass bowl and get collected at the bottom. A baffle plate is provided
to prevent the turbulent air from splashing the water into the filter cartridge. At the bottom of
the filter bowl there is a drain plug which can be opened manually to drain off the settled
water and solid particles.
Dryer:
The dryer can be of the refrigerated type or the chemical type. When absolute dry air is
needed, the chemical dryer is used. This can be of the adsorption type or the absorption type
(deliquescent type).
Figure 4
The absorption type of dryer shown in fig. 4 uses chemical agents like phosphoric pentoxide
or calcium chloride as drying agents. The moisture in the compressed air chemically reacts
with the drying agent. The agent dissolves to form a liquid compound which collects at the
bottom of the dryer where it can be drained out. The deliquescent agent has to be replenished
regularly as it gets consumed during the drying process.

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Air Service unit:

This unit is positioned between the receiver tank and the load to be moved. It is made of three
parts- Air Filter, Pressure Regulator and the Lubricator.
1) Air Filter: It is similar to the main-line filter described above.
2) Pressure Regulator:
This can be either a relief valve or a non-relieving pressure regulator.
(a) Relief valve:
Figure 5
It consists of ball type valve held on to the valve seat by a spring in tension. The spring
tension can be adjusted by using the adjusting cap. When the air pressure exceeds the spring
tension pressure the ball is displaced from its seat, thus releasing the air and reducing the
pressure. A relief is specified by its span of pressure between the cracking and full flow,
pressure range and flow rate. Once the valve opens (cracking pressure), flow rate depends on
the excess pressure. Once the pressure falls below the cracking pressure, the valve seals itself.
(b) Non-relieving pressure regulator:

In a non-relieving pressure regulator (Fig. 6) the outlet pressure is sensed by a diaphragm
which is preloaded by a pressure setting spring. If outlet pressure is too low, the spring forces
the diaphragm and poppet to move down thus opening the valve to admit more air and raise
outlet pressure. If the outlet pressure is too high the air pressure forces the diaphragm up
hence reduces the air flow and causing a reduction in air pressure. The air vents away through
the load. At steady state condition the valve will balance the force on the diaphragm from the
outlet pressure with the preset force on the spring.
VALACHIL, MANGALURU
Figure 6
Lubricator:
The compressed air is first filtered and then passed through a lubricator in order to form a
mist of oil and air to provide lubrication to the mating components. Figure 7 shows the
schematic of a typical lubricator. The principle of working of venturimeter is followed in the
operation of lubricator.
Figure 7
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The compressed air from the dryer enters in the lubricator. Its velocity increases due to a
pressure differential between the upper and lower chamber (oil reservoir). Due to the low
pressure in the upper chamber the oil is pushed into the upper chamber from the oil reservoir
through a siphon tube with check valve. The main function of the valve is to control the
amount of oil passing through it. The oil drops inside the throttled zone where the velocity of
air is much higher and this high velocity air breaks the oil drops into tiny particles. Thus a
mist of air and oil is generated. The pressure differential across chambers is adjusted by a
needle valve. The air-oil mixture because of high velocity of air swirls as it leaves the central
tube resulting in throwing out of excess oil particles into the oil bath.
FRL UNIT:
It is possible to have the three elements namely Filter, Regulator and Lubricator to be
combined into one unit called the FRL unit.
- The filter is of the sintered type with water separator.
- The regulator is of the non-relieving type.
- The lubricator is of the mist type. The required lubrication is set by adjusting the
needle valve.
An FRL unit is schematically shown in fig 8 along with its ANSI symbol.
Figure 8

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PNEUMATIC ACTUATORS:
In a pneumatic system, an actuator is a device which converts energy from compressed air
into the required type of action or motion.
Pneumatic actuators are broadly classified into:
1. Linear Cylinders
2. Rotary Actuators
1. LINEAR CYLINDERS (AIR CYLINDERS):
A linear cylinder converts pneumatic energy into linear motion. A linear cylinder can be
single acting or double acting.
(a) Single acting cylinder:
In this cylinder, the compressed air is fed only in one side which will extend the
cylinder (piston). The work can be produced only in one direction. The return
movement of the piston is effected by a built-in spring or by the application of an
external force. If the cylinder is used to lift a load, the retraction happens by gravity.
Construction:
A single acting cylinder is made up of the following elements:
 The cylinder body (tube)
 End covers
 Piston
 Piston rod
 U –cup seal
 O-ring
 Bush or Bearing to guide the piston rod.
 Built-in spring
Figure 9

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The compressed air pushes the piston located in the cylindrical tube causing the
desired motion. The return stroke takes place by the action of a spring. Generally the
spring is provided on the rod side of the cylinder.
(b) Double acting cylinder:

In a double acting cylinder, each end is pressurised by compressed air alternately thus
developing force in either direction. Hence the piston can do work not only during
advance movement but also on the return.
Construction:
The main parts of the double acting cylinder are
 Base cap with port connection
 Bearing cap with port connection
 Cylinder barrel
 Piston
 Piston rod
 Scrapper rings
 Seals
Figure 10
The piston rod is connected to piston head and the other end extends out of the
cylinder. The piston divides the cylinder into two chambers namely the rod end side
and piston end side. The seals prevent the leakage of oil between these two chambers.
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The cylindrical tube is fitted with end caps. The pressurized oil, air enters the cylinder
chamber through the ports provided. In the rod end cover plate, a wiper seal is
provided to prevent the leakage of oil and entry of the contaminants into the cylinder.
The end caps may be attached to the tube by threaded connection, welded connection
or tie rod connection. The piston seal prevents metal to metal contact and wear of
piston head and the tube. These seals are replaceable.
Working:
Compressed air is allowed into the piston through the extend port. The piston extends
and the air on the rod side escapes through the retract port. Delivery of compressed air
into the cylinder continues till the extension is complete. Similarly, compressed air is
allowed into the cylinder through the retract port and the piston retracts. The air in the
piston side escapes through the extend port during retraction. Air entry continues till
retraction is completed.
End position cushioning:
Double acting cylinders generally contain cylinder cushions at the end of the cylinder
Cushioning arrangement avoids the damage due to the impact occurred when a fast
moving piston is stopped by the end caps.
Figure 11
Deceleration of the piston starts when the tapered plunger enters the opening in the
cap and closes the main fluid exit. This restricts the exhaust flow from the barrel to
the port. This throttling causes the initial speed reduction. During the last portion of
the stroke the oil has to exhaust through an adjustable opening since main fluid exit
closes. Thus the remaining fluid exits through the cushioning valve. Amount of

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cushioning can be adjusted by means of cushion screw. A check valve is provided to

achieve fast break away from the end position during retraction motion. A bleed
screw is built into the check valve to remove the air bubbles present in a hydraulic
type system.
SPECIAL TYPES OF CYLINDERS:

 Telescopic cylinder
 Tandem cylinder
 Rod less cylinder
 Impact cylinder
 Duplex cylinders
 Cylinders with sensors
Telescopic cylinder:
Telescopic cylinder is used when long stroke length and short retracted length are required.
They extend in stages, each stage consisting of a sleeve that fits inside of the previous stage.
Figure 12 shows the construction of a typical double acting telescopic cylinder with two
pistons (Two stages).
Figure 12
Extension stroke: When the pressure is applied at port A, air flows through port X and Y and
pressure is applied on both sides of Piston 1. But difference in areas causes the piston 1 to
move to the right. Once the piston 1 fully extends, inner piston 2 will extend.
Retraction stroke: To retract, air is applied to port B. Air pressure will act on the annulus of
the inner piston 2 and moves inner piston 2 to the left. When the inner piston moves to left

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and starts to close port X, air which entered from port B goes to annular side of the piston 1
via port Y and pushes the piston 1 to the left.
Tandem Cylinder:
Figure 13
Tandem cylinders are two separate double acting air cylinders arranged in line to one cylinder
body so that the power generated by the two is added together, thereby approximately
doubling the piston output. A tandem cylinder is used in applications where a large amount of
force is required from a small-diameter cylinder. Basically, a tandem cylinder is simply two
or more separate cylinders stacked end to end in a unit and with all the pistons mounted on a
common piton rod. Pressure is applied to both pistons, resulting in increased force because of
the larger area. The drawback is that these cylinders must be longer than a standard cylinder
of larger flow rate than a standard cylinder to achieve an equal speed because flow must go to
both pistons.
Rod less cylinders:
A rod less air cylinder differs from a basic air cylinder in that no piston rod extends outside
the cylinder body. Instead, the internal piston is connected to an external carriage, by means
of a magnetic or mechanical coupling system
There are three types of rod less cylinders. They are
1. Cable Cylinder
2. Sealing band Cylinder with slotted cylinder barrel
3. Cylinder with Magnetically Coupled Slide
Cable cylinder:
This type of cylinder has a piston that can reciprocate inside the cylinder barrel. The ends of
the barrel are sealed with gland seals. An endless nylon jacketed cable which passes through

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the gland seals connects the two ends of the piston. This cable passes over two pulleys and a
carriage moves over the cable.
Figure 14
When compressed air enters the cylinder the piston moves from end-to-end. The cables which
are attached to either side of the piston and extend out at the ends of the cylinder move as
well. Depending on the direction of the piston both the carriage and any on-carriage tooling
moves towards one end of the air cylinder or the other.
Cylinder with Magnetically Coupled Slide:
Figure 16
This cylinder consists of a cylindrical barrel, a piston and two slides. The piston in the
cylinder is freely movable according to pneumatic actuation. The slide is attached on to the
outer surface of the cylinder and can slide over it. Both the piston and the slide are fitted with
a set of annular permanent magnets. Thus a magnetic coupling is produced between the slide
and the piston. As soon as the piston is moved by compressed air, the slide moves
synchronously with it. The cylinder barrel is hermetically sealed from the outer slide. There
are no leakage losses.

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CYLINDER MOUNTINGS:
Figure 17
.
2. ROTARY ACTUATORS:
While the most often used actuators for pneumatic drives are cylinders for translational
movements, there are many applications that require a turning or twisting movement of up to
360 degrees. Examples are turning components over in a drilling jig, providing a wrist action
on a pick-and-place device or operating process valves.
These actuators are called rotary actuators. Hence, rotary actuators are devices which produce
high torque output and have a limited rotary movement. Standard rotations are 90° , 180°
and 270° . They are used in bench grinders, agitators, mixers, feeders, hoists, vibrators, etc.
Rotary actuators are mainly available in three designs.
a) Vane type limited rotation motors
b) Rotary Actuator of Rack and Pinion Type
c) Helix spline rotary actuator
a) Vane type limited rotation motors:

The vane actuator consists of a cylindrical housing, through which passes a central shaft and
to which the vane is rigidly attached. The housing has shoe or a stopper fixed to its internal
diameter as shown in fig 16, thus dividing the interior space into two chambers. Pressurised
air enters through port A and rotates the vane in the clockwise direction and air in the other

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chamber moves out of the port B. Similarly, when the air pressure is applied to the port B, the
vane rotates in anti-clockwise direction and air in the other chamber moves out of the port A.
Design geometry normally limits the rotary movement of a single vane actuator to about 280°
maximum.
Figure 18
b) Rotary Actuator of Rack and Pinion Type:
This type of actuator has a high torque and small installation dimensions. There are two
pistons which transmit the turning moment to the output shaft. The toothed piston rods act
on the output shaft in a rack-and-pinion type arrangement. Each piston and toothed rod is
of integral construction. The rack-and pinion type arrangement gives an even turning
moment throughout the rotation movement.
Figure 19

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c) Helix spline rotary actuator:

The spiral-shaft rotary actuator has a keyed, non-rotating piston with a hollow rod. The
hollow rod has a set of internal spiral grooves that mesh with the spiral shaft. The spiral-
grooved shaft only has rotational movement and extends through the housing as an output
shaft. With fluid piped to the CW port, the output shaft turns clockwise. With fluid piped to
the CCW port, the output shaft turns counter clockwise.
Figure 20
PNEUMATIC CONTROL VALVES:

In a pneumatic system, valves are elements used for controlling and regulating the working
medium namely air. Broadly, these valves are used to:
i) Start and stop pneumatic energy
ii) Control the direction of flow of compressed air
iii) Control the flow rate of compressed air
iv) Control the pressure rating of compressed air.
Accordingly these valves may be grouped as:
1. Direction control valves
2. Non-return valves
3. Flow control valves
4. Pressure control valves.

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DIRECTION CONTROL VALVES:

The function of directional control valves is to control the direction of flow in the pneumatic
circuit. DCVs are used to start, stop and regulate the direction of air flow and to help in the
distribution of air in the required line.
Symbolic representation of DCV:
A Direction control valve has generally two, three, four or five ports or openings or ways.
The ports are designated by letters or alphabets such as
P : Compressor line port
R : Exhaust port
A,B : Working ports
A direction control valve has two or three working positions generally. They are:
 Normal or zero position (natural) or neutral position
 Working position (the working position can be two or more)
The positions are mostly numbered as 0, 1, 2. Direction control valves are designated to
indicate both the number of the ways as well as the number of working positions such as
4/2,3/2 direction control valve etc., (This means a 4 ways/ 2 position valve, 3 ways/ 2position
valve etc.

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Neutral position: In a DCV with spring return, the neutral position is defined as the position
to which the valve returns after the actuating force has been withdrawn. In all fluid power
control systems, the neutral position is indicated as "0".
Starting position: The starting position or initial position is defined as the position taken up
by the valve (due to spring in-case of spring actuated D.C. valve) after installation.
Working position: The position attained by the valve when actuated.
However, as per the ISO 5599, ports are designated using a number system.
The equivalent notations in both the systems are listed below:
Using the above notations the different DCVs are listed below:
Table 1: Port designation of DCV

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Classification of DCV:
Direction control valves are classified in the following ways:
1. Based on the number of ports or flow paths:
a) Two way valves
b) Three way valves
c) Four way valves
2. Based on construction:
a) Poppet valves or seat valves
b) Spool valve
c) Suspended seat type slide valve
3. Based on the method of actuation:
a) Manually operated
b) Mechanically operated
c) Electrically operated
d) Pneumatically operated
POPPET TYPE DCV:
There are two different types of poppet valves, namely ball seat valve and disc seat valve.
Ball Seat Valve:
Figure 19 shows the construction of a simple 2/2 normally closed valve. If the push button is
pressed, ball will lift off from its seat and allows the air to flow from port P to port B. When
the push button is released, spring force and air pressure keeps the ball back and closes air
flow from port P to port B.
Figure 21

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Disc Seat Valve:

Figure 20 shows the construction of a disc type 3/2 way DCV of the normally closed type.
Figure 22
In the normal position when the push button is released, ports 2 and 3 are connected via
hollow pushbutton stem. If the push button is pressed, port 3 is first blocked by the moving
valve stem and then valve disc is pushed down so as to open the valve thus connecting ports 1
and 2. When the push button is released, spring and air pressure from port 1 close the valve.
SPOOL TYPE DCV:

In this type of DCV, the valve element is a spool which slides inside a finely finished bore of
the valve body.
2/2 DCV:
Fig 21 shows a 2/2 DCV of spool type.
Figure 23

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When the push button is not actuated, no air moves from P to A. This is the neutral or initial
position of the valve. As the spool is moved against the spring, the spool shifts and port P
connects to port A and air passes from P to A. This is the working position of the valve.
3/2 DCV:
Fig 22 shows a 3/2 DCV of spool type.
Figure 24
This valve has three ports P, A and R. The valve element is a spool actuated by a push button
tappet and a spring. In the neutral position shown in figure, 'P' is closed and 'A' opens to ‘R’.
As the spool is actuated, it shifts and 'A' gets connected to 'P' and 'R' closes. Due to the
movement of the spool, the spring gets compressed. When the actuating force on the push
button is released, the valve returns to its original position connecting' A' to 'R' and effecting
the closure of P.
5/2 DCV:
Figure 23 shows a 5/2 DCV of spool type.
Figure 25
(i) Position 1. When the spool is actuated to the left, port P gets connected to 'B' and 'S'
remains closed while A gets connected to 'R'

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(ii) Position 2. When the spool is actuated to the right, port 'P’ and 'A' get connected to
each other and 'B' to 'S' while port 'R' remains closed.
Suspended seat type slide valve:

In this type of DCV, a suspended disc controls the opening and closing of ports by making a
relatively small movement. This suspended disc can be moved by pilot pressure at port 14 or
at port 12. When the pilot pressure acts through port 12 as shown in fig 25(a), the ports 1 - 2
and 4 - 5 are connected and 3 is blocked. When the air is given to pilot line 14 as shown in
fig. 25(b), then 2 - 3 and 4 -1 are connected and 5 is blocked.
Figure 26 (a)
Figure 26 (b)
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Methods of actuation of DCV:

The methods of actuation of pneumatic directional control valves depend upon the
requirements of the task.
Figure 27
NON RETURN VALVES:

Non return valves permit flow of air in one direction only, the other direction through the
valve being at all times blocked to the air flow.
Among the various types of non-return valves available, those preferentially employed in
pneumatic controls are as follows:
1. Check valve
2. Shuttle valve
3. Twin pressure valve
4. Quick exhaust valve

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CHECK VALVE:
A check valve completely blocks air flow in one direction while permitting flow in the
opposite direction with minimum pressure loss across the valve. As soon as the inlet pressure
in the direction of free flow develops a force greater than that of the internal spring, the check
is lifted clear of the valve seat. The check in such valve may be plug, ball, plate or
diaphragm.
Figure 28
SHUTTLE VALVE:
A shuttle valve also known as a double check valve, allows air pressure in a line to be
obtained from alternative sources. It can have a ball or a cylindrical disc as the valve element
moving inside the bore in the valve housing.
Figure 29
There are three openings P1, P2 and A. If an air signal is fed to port P1 the ball moves, closing
port P2 and air passes to 'A'. If the air is fed to port P 2, port P1 is closed and air moves to 'A'. If
air is fed simultaneously to port P1 and P2 then air moves to 'A' either from P1 or P2 or from
both. This element is also called an OR gate.

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TWIN PRESSURE VALVE:

A twin pressure valve requires two pressurised inputs to allow an output from itself. That is,
an output is produced if both the input signals are fed. Hence it is also called an AND gate
valve. The valve has a spool as the valve element.
Figure 30
There are three ports-two signal receiving ports 'A' and 'B' (input) and .an outlet port 'Y'.
When signal is fed to 'A' first, the valve spool moves towards 'B', closing the air passage from
'A' to 'Y' and hence the air from 'B' moves to 'Y'. The reverse takes place if air is fed first to
'B'. Then air moves from 'A' to 'Y'. If air is fed simultaneously to both 'A' and 'B', then the
spool remains in its already acquired position and air may pass to 'Y' from both 'A' and 'B' or
from any of these two depending on the air pressure and spool position.
QUICK EXHAUST VALVE:

The quick exhaust valve is used to exhaust the cylinder air quickly to atmosphere. In many
applications especially with single acting cylinders, it is a common practice to increase the
piston speed during retraction of the cylinder to save the cycle time. The higher speed of the
piston is possible by reducing the resistance to flow of the exhausting air during the motion of
cylinder. The resistance can be reduced by expelling the exhausting air to the atmosphere
quickly by using Quick exhaust valve.
It consists of a movable disc (also called flexible ring) and has three ports:
 Supply port 1, which is connected to the output of the final control element
(Directional control valve).
 The Output port, 2 of this valve which is directly fitted on to the working port of
cylinder.
 The exhaust port, 3 which is left open to the atmosphere.
VALACHIL, MANGALURU
Figure 31
Forward Motion: During forward movement of piston, compressed air is directly admitted
behind the piston through ports 1 and 2 Port 3 is closed due to the supply pressure acting on
the diaphragm. Port 3 is usually provided with a silencer to minimise the noise due to
exhaust.
Return Motion: During return movement of piston, exhaust air from cylinder is directly
exhausted to atmosphere through opening 3 (usually larger and fitted with silencer) . Port 1 is
sealed by the diaphragm. Thus exhaust air is not required to pass through long and narrow
passages in the working line and final control valve.
FLOW CONTROL VALVE:

A flow control valve serves to control the speed of an actuator in a pneumatic system. This is
done by constricting or throttling a flow passage so that part of the air supply is obstructed in
the area of constriction. Both fixed and variable type flow control valves are used in
pneumatic systems.
Flow control valves are available in two modes
1. Fixed flow control
2. Variable flow control
In fixed flow controlling, the control passage is not adjustable.
In a variable control valve, an adjustable control needle is positioned at any place of the flow
passage to regulate the flow as per need of flow quantity. This is done by screwing a taper
needle inside the control passage.
The variable flow control can be either one way valve or two-way valve.

VALACHIL, MANGALURU
(a) Two-way variable flow control valve:

In this valve, air can flow in both directions and in both directions it is subjected to
throttling due to a variable constriction provided in the passage. An adjustable needle
valve controls the size of the opening.
Figure 32
(b) One-way variable flow control valve:
In this valve, air can flow through two paths in one direction – one through the
constricted opening and the other through the check valve. However, in the opposite
direction the check valve does not allow it to pass through and the air is forced
through the constricted opening.
Figure 33

VALACHIL, MANGALURU
TIME DELAY VALVE:

Sometimes it becomes necessary to create time delay of signals in pilot operated pneumatic
circuits. A time delay valve can be used in such cases.
A time delay valve consists of an in-built air reservoir, an in-built non-return flow control
valve and a pilot controlled spring return 3 way 2 position direction control valve.
Fig. 34 shows the construction of the time delay valve.
Figure 34(a)
When the compressed air is supplied to the port 'P' of the valve, it is prevented from flowing
to port 'A' from 'P', as this is blocked by the spring actuated spool. Air is accumulated in an
in-built reservoir of the valve from the pilot control port 'Z', the control passage of the same
being controlled by the needle of the in-built throttle valve. Pressure starts building up here.
When the pressure needed to push the spool is built-up in the reservoir, the pilot spool of the
3/2 direction control valve shifts, thus opening port 'P’ of the main valve to. ‘A' and closing
'R'. The time required to build-up the pressure in the reservoir, is the amount of delay time
offered by the time delay valve. With further increase of pressure, the inbuilt check valve
opens; the air from the reservoir gets exhausted and the valve spool returns to its original
position.
The time delay valve is represented by the symbol shown in fig 35(b)
Figure 34(b)

VALACHIL, MANGALURU
PRESSURE CONTROL VALVES:

A pressure control valve controls the pressure of the air flowing through the valve or
confined in the system controlled by the valve.
There are three types of pressure control valves
1. Pressure limiting valve or Pressure relief valve
2. Pressure sequence valve
3. Pressure regulator or pressure reducing valve
Pressure relief valve (Pressure limiting valve):

A pressure relief valve prevents the pressure in a system from rising above a permissible
maximum. This valve performs a safety relief function by opening to the atmosphere if a
predetermined pressure is exceeded in the system, thus releasing the excess pressure. As soon
as the pressure is thus relieved to the desired value, the valve closed again by spring force.
Figure 35
Pressure Sequence valve:
A pressure sequence valve is incorporated into a pneumatic control circuit where a certain
minimum pressure must be available for a given function and operation is not be initiated at
any pressure lower than that.
Fluid at the inlet port of the valve cannot pass to the secondary circuit or outlet port, until
reaching set pressure. Upon reaching set pressure, the valve opens enough to let excess pump
flow pass on to the second operation.

VALACHIL, MANGALURU
Figure 36
Pressure reducing valve (pressure regulator):

Pressure regulators, commonly called pressure-reducing valves, maintain constant output
pressure in compressed-air systems regardless of variations in input pressure or output flow.
A standard reducing valve is normally open. When downstream pressure goes higher than its
setting, the valve closes, blocking flow. If pressure downstream tries to increase — say due to
resistance from an opposing cylinder — a reducing valve also blocks reverse flow.
Figure 37

VALACHIL, MANGALURU
QUESTION BANK
1. List the advantages and limitations of the pneumatic systems.
2. What are the characteristics of compressed air?
3. What are the considerations involved in deciding the medium for a fluid power system?
4. With a neat sketch, briefly explain the components in a pneumatic system. Describe the
working of the system.
5. How are air compressors classified?
6. Write a note on fluid conditioner in a pneumatic system.
7. With a neat diagram, explain the working of main line filter used in the pneumatic
system.
8. With a neat diagram, explain the working of dryer used in the pneumatic system.
9. What is FRL unit? Write its symbol and breifly explain its components.
10. With a neat diagram, explain the relief valve type of regulator used in the pneumatic
system.
11. With a neat diagram, explain the non-relieving pressure regulator used in the pneumatic
system.
12. With a neat diagram, explain the working of lubricator used in the pneumatic system.
13. With a neat diagram, explain the construction and working of a single acting pneumatic
cylinder.
14. With a neat diagram, explain the construction and working of a double acting pneumatic
cylinder.
15. With a neat diagram, explain the process of cushioining of pneumatic cylinders.
16. With neat sketches, explain the construction and working of the following types of
pneumatic cylinders:
(a) Telescopic cylinder
(b) Tandem cylinder
(c) Rodless cylinder
17. Draw neat sketches to show the various cylinder mountings.
18. With neat sketches, explain the construction and working of the following rotary type
pneumatic actuators:
(a) Vane type limited rotation motors
(b) Rotary Actuator of Rack and Pinion type
(c) Helix spline rotary actuator
19. With examples, explain the notations used in specifying direction control valves in
pneumatic systems.
20. With neat diagrams explain the construction and working of the following direction
control valves:
(a) Ball seat valve
(b) Disc seat valve
(c) 2/2 spool type DC valve
(d) 3/2 spool type DC valve
(e) 5/2 spool type DC valve
(f) 5/2 suspended seat type slide

VALACHIL, MANGALURU
21. Explain with neat sketches, the working of the following non-return valves:
(a) Check valve
(b) Shuttle valve
(c) Twin pressure valve
(d) Quick exhaust valve
22. Explain with neat sketches, the working of the following flow control valves:
(a) Check valve
(b) Shuttle valve
23. What is a Time delay valve? Explain its working with a neat diagram.
24. Explain with neat sketches, the working of the following pressure control valves:
(a) Pressure relief valve
(b) Pressure sequence valve
(c) Pressure reducing valve

VALACHIL, MANGALURU

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SUBJECT: FLUID POWER SYSTEMS (17ME72)

MODULE 4: PNEUMATIC POWER SYSTEMS

INTRODUCTION TO PNEUMATIC SYSTEMS:

Advantages of Pneumatic systems:

Limitations of Pneumatic systems:

NOTES BY SANDESH M PRABHU,

Applications of Pneumatic systems:

Characteristics of compressed air:

Choice of working medium and system:

NOTES BY SANDESH M PRABHU,

 Air is used where quick response of actuator is required.

Structure of Pneumatic control system:

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

i) Single acting compressor: The compression takes place in the space on

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

Air Service unit:

(b) Non-relieving pressure regulator:

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

(b) Double acting cylinder:

NOTES BY SANDESH M PRABHU,

cushioning can be adjusted by means of cushion screw. A check valve is provided to

SPECIAL TYPES OF CYLINDERS:

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

a) Vane type limited rotation motors:

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

c) Helix spline rotary actuator:

PNEUMATIC CONTROL VALVES:

NOTES BY SANDESH M PRABHU,

DIRECTION CONTROL VALVES:

NOTES BY SANDESH M PRABHU,

Table 1: Port designation of DCV

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

Disc Seat Valve:

SPOOL TYPE DCV:

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

Suspended seat type slide valve:

Methods of actuation of DCV:

NON RETURN VALVES:

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

TWIN PRESSURE VALVE:

QUICK EXHAUST VALVE:

FLOW CONTROL VALVE:

NOTES BY SANDESH M PRABHU,

(a) Two-way variable flow control valve:

NOTES BY SANDESH M PRABHU,

TIME DELAY VALVE:

NOTES BY SANDESH M PRABHU,

PRESSURE CONTROL VALVES:

Pressure relief valve (Pressure limiting valve):

NOTES BY SANDESH M PRABHU,

Pressure reducing valve (pressure regulator):

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,