PNEUMATICS

WHAT IS PNEUMATICS?
• Pneumatics is a science that deals with transmission of
energy using compressed air.

• It is a branch of physics that deals with the study of

gases especially air, its mechanical properties and
applications at pressures higher (compressed) or lower
(vacuum) than the atmospheric pressure.

• It is the industrial implementation and application of

air powered actuators (cylinders and motors) and their
control devices (valves) needed in their operation.

• PNEUMA - Greek root term means “breath” or “wind”

WHY DO IT YOURSELF……………
WHEN IT CAN BE DONE WITH AIR?
 PRESSURE = FORCE / AREA;
1 PASCAL = 1NEWTON / METER2

STANDARD PNEUMATIC PRESSURES:

= 4 TO 6 BARS (NORMAL)
= 10 BARS (MAXIMUM)
FORCE < 3 TONS FOR PNEUMATICS
FORCE > 3 TONS FOR HYDRAULICS
CONVERSIONS:
1 BAR  100 KPA = 14.5 PSI
1 ATMOSPHERIC PRESSURE
= 1.01325 BAR
 SOME INDUSTRIAL APPLICATIONS:
• TRANSFER & HANDLING OF MATERIALS
• PACKAGING
• MACHINE TOOL, WORK OR TOOL FEEDING
• FORMING OPERATION
• SORTING OF PARTS OR PRODUCTS
• OPERATION OF HEAVY OR HOT DOORS
• BOTTLING AND FILLING MACHINES
• PNEUMATIC ROBOT
• STAMPING AND EMBOSSING COMPONENTS
• HOLDING FOR GLUING, HEAT SEALING OR WELDING PLASTICS
PNEUMATIC APPLICATION (PRODUCT MONITORING)
PACKAGING OF TEA
REFILLING STATION
AUTOMATIC PACKAGING OF FRUITS
 COMPRESSED AIR AS A WORKING MEDIUM
ADVANTAGES:
• AIR IS AVAILABLE EVERYWHERE.
• COMPRESSED AIR IS EASILY CONVEYED IN PIPELINES OVER LARGE DISTANCES
AND THERE IS NO NEED TO RETURN IT.
• COMPRESSED AIR IS INSENSITIVE TO TEMPERATURE FLUCTUATIONS
• COMPRESSED AIR CAN BE STORED
• COMPRESSED AIR IS EXPLOSION PROOF
• COMPRESSED AIR IS CLEAN
• COMPRESSED AIR IS FAST (SPEED OF CYLINDERS: 1-2 M/SEC)
• STRAIGHT LINE MOVEMENT CAN BE PRODUCED DIRECTLY
 COMPRESSED AIR AS A WORKING MEDIUM

DISADVANTAGES
• COMPRESSED AIR IS A RELATIVELY EXPENSIVE MEANS OF
CONVEYING ENERGY
• COMPRESSED AIR REQUIRES GOOD CONDITIONING
• IT IS ONLY ECONOMICAL UP TO A CERTAIN FORCE EXPENDITURE
• AIR IS COMPRESSIBLE, UNIFORM PISTON SPEED IS IMPOSSIBLE
• EXHAUST AIR IS LOUD (REDUCED BY USING SILENCERS)
 MACHINE, INSTALLATION

• Cylinders
• Rotary actuators
Drive Elements • Compressed-Air Motors
• Sub-assemblies

Actuators, Controlling • Directional-control valves

Elements • Flow-control valves
• Non-return valves
and Signaling Elements • Pressure-control valves

• Filters
Air-service Units • Regulators
• Lubricators

• Drive assembly and Compressor

CENTRAL COMPRESSED-AIR • Reservoir
UNIT • Compressed-air Drier and Cooler
• Conditioning equipment
PNEUMATIC SYSTEM STRUCTURE & SIGNAL FLOW

ACTUATING
DEVICES

FINAL CONTROL
ELEMENT

PROCESSING
ELEMENTS

INPUT
ELEMENTS

ENERGY SUPPLY
PNEUMATIC CONTROL SYSTEM
AND SIGNAL FLOW
 AIR SERVICE UNIT (FRL)
CONSISTS OF AN AIR FILTER, PRESSURE REGULATING VALVE WITH
PRESSURE GAUGE AND A COMPRESSED AIR LUBRICATOR.

AIR FILTER - FILTERS THE COMPRESSED AIR OF ALL IMPURITIES OR DUST

PARTICLES AND ANY CONDENSATE IT CONTAINS.

PRESSURE REGULATOR - A REDUCING VALVE IS ASSIGNED THE DUTY OF

MAINTAINING A RELATIVELY CONSTANT OPERATING PRESSURE
REGARDLESS OF FLUCTUATION AND CONSUMPTION RATE.

COMPRESSED AIR LUBRICATOR - USED TO PROVIDE THE PNEUMATIC

COMPONENTS WITH SUFFICIENT LUBRICATION. THESE LUBRICANTS
INHIBIT THE WEARING OF ALL MOVING PARTS, KEEP FRICTIONAL
FORCES TO A LOW LEVEL, AND PROTECT THE EQUIPMENT FROM
CORROSION.
 THE PURPOSE OF AIR SERVICE UNIT
❖ To clean the compressed air from dust/dirt and particles that
might reach the cylinders and valves of the system. This will
increase the life of the components in the system.
❖ To separate the moisture/water from the compressed air. This
avoids rust of the pneumatic components.
❖ To regulate and maintain a constant air pressure in the system.
❖ To lubricate the compressed air with oil.
3/2 way Pressure Regulato Filling Valve 3/2 way
Shut-off Valve r Shut-off Valve

Filter with Water T

Pressure Gauge Lubricator
rap
 Pressure Dosing Screw
Regulator
Filler Plug
Deflector
Tunnel

Atomizer Nozzle

Sinter Filter
Element Condensate Deflector Plate
Drain

Cross-sectional view of the component’s construction

 Air-service Unit

Air-service Unit
Filter with Water Trap Manual Control
Filters remove contaminants, mainly co
ndensed water from compressed air. Co Inlet Outlet
mpressed air is conducted into the filter
bowl and is rotated at high speed. Heav
y particles of dirt and water particles ar
e centrifuged onto the wall of the filter
bowl and they remain there.
Condensed water accumulates in the lo
wer part of the filter bowl and is draine
d through the drain plug when the wate
r reaches the maximum level mark. Baffles

Filter Element

Water Trap
Drain 19
LUBRICATOR
AIR FLOWS THROUGH
THE LUBRICATOR
FROM LEFT TO RIGHT.
SOME OF THE AIR
FLOWING THROUGH
THE VALVE IS GUIDED
THROUGH A NOZZLE.
DUE TO THE
RESULTING PRESSURE
DROP, OIL IS DRAWN
FROM AN OIL
RESERVOIR THROUGH
A FEED PIPE.
 Pressure Regulator with Relief Port

Inlet Outlet
Pressure operation

Valve Body
Vent

Spring and
Adjusting screw
21
DRIVE ELEMENTS
Pneumatic drive elements convert the energy in the compressed
air into force and motion. The pneumatic drive elements can
move in a linear, reciprocating or rotating motion.
SINGLE-ACTING CYLINDERS

The single-acting cylinder converts the compressed air

energy into mechanical energy in the form of force and linear
movement in one direction only.
The compressed air is applied only on the bottom side of the
piston that is why the cylinder can move loads or
perform mechanical work in a forward motion only and that the
effective force is reduced by the return spring.
Single-acting cylinders are used in the assembling and
packing automated lines to move, lift, feed, eject, press or push
objects or to clamp parts. Practically, they are suitable for oil-free
operation.
 Pressure Port Exhaust Port
Rod
Piston Spring

Piston
Area Bush & Sealing Elem
ent

Base end Cov Tube Head end Cove

er Annular Area r

Cross-sectional view of the component’s construction

Single-Acting Cylinder, Spring Return

 Special versions of the Single-acting cylinder

An alternative construction is a single-acting cylinder, spring extend

with a spring in the piston area causing the piston to extend. Such
pistons are used in the automotive industry and these are mounted in
the air brakes for vehicles and trains.

Load
Single-Acting Cylinder, Spring Extend

Another special form of single-acting cylinders is si

ngle-acting cylinder, without return spring in which
the piston’s return stroke is caused by external for
ces or by its own weight.

Single-Acting Cylinder, without Return Spring

 DOUBLE-ACTING CYLINDERS
The double-acting cylinder converts the
compressed air energy into mechanical energy in the form
of force and linear movement in both directions.
This type of cylinder has two ports. The compressed air
is applied at one of the working ports while the other
working port is vented. They are used when the piston rod
must perform work during its return stroke and when
longer strokes are needed.
Are used for moving, pressing and lifting in
pneumatic manipulators and automatic packaging
machines.
Types of Double-Acting Cylinders

1. Piston cylinders
- Stroke lengths are up to 2000 mm.
- The working speed is in the range of 30 to 2000 mm/s.
- Cylinder forces are about 40 kN.
2. Short-stroke Cylinders
- Short-stroke cylinders are used when short strokes are require
d together with high forces.

Double-Acting Cylinder

Double-Acting Cylinder
with Adjustable Stroke Cushioning
 Cushion / C Plunger
Adjustable T
Bottom ap Seal hrottle
Tube

Piston
Area

Piston Port Cover Rod

Annular Area
Cross-sectional view of the component’s construction

Typical picture of Short-stroke Cylinders

 MODE OF OPERATION

Piston Area

Piston Annular Area

When the piston area is connected to the pressure

line and in the same time the annular area is connected
to the atmosphere, the piston of the double acting
cylinder moves forwards.
Operation of Double Acting Cylinders with Air
Cushioning

Cushioning
sleeves Seals
Non-return valve

Cushioning adjustment
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
Operation of Double Acting Cylinders with Air
Cushioning
 ROTARY ACTUATORS

The rotary actuators transform the power of

compressed air that generates linear piston mo
vement into a reversible rotary movement. The
piston rod of the actuator is designed in the f
orm of a toothed rack with two pistons conn
ected at each end.
.
Port Tube Port

Cover Shaft with Pinion Cover

Typical picture of a Rotary Actuator

Cover Rack Piston Cover

Piston Tube Pinion Port

Cross-sectional view of the component’s construction

Rotary Actuator
 MODE OF OPERATION

Left Piston Left Piston Area

Left Cylinder Cover Right Piston Area

When the left piston area is connected to the

atmosphere and in the same time the right piston
area is connected to the pressure line, the left
piston is pressed to the left cylinder cover.
 MODE OF OPERATION

Left Piston Area Rack

Pinion Right Piston Area

Similarly, when the left piston area is connected to the pres

sure line and the right one is connected to the atmosphere
the two pistons with the rack move to the right and the
rack turns the pinion clockwise.
 MODE OF OPERATION

Left Piston Left Piston Area

Left Cylinder Cover Right Piston Area

Again, when the left piston area is connected to the

atmosphere and the right one is connected to the pressure
line the two pistons with the rack move to the left and the ra
ck turns the pinion counter clockwise.
SLIDE UNITS

A slide unit is a precision linear actuator

of compact dimensions which can be
used on manufacturing and assembly
robotic machines. Precise machine work Typical picture of Slide Units
mounting sur-faces and parallel piston
guide rods ensure accurate straight
line move- ment when built as part of
the cons- truction of a transfer and
position machine.
 RODLESS CYLINDER

The Rodless cylinders are particularly suitable for very long

piston strokes. A carriage is magnetically attached to the
cylinder which was made of a non-magnetic material like
brass, by way of the magnetic piston.

Typical picture of a Rodless Cylinder

Typical picture of a Rodless Cylinder

Rodless Cylinder
 ADVANTAGE OF THE RODLESS CYLINDER
Conventional Double Acting Cylinders require space to house the
cylinder. Plus space to carry out the work.

More effective use of the available space can be made by

using Rodless Cylinders
 HOLLOW ROD CYLINDER

The hollow rod cylinder provides a direct connection

between vacuum generating equipment and a vacuum
pad attached to the rod working end. The connecting
tube at the rear end of the cylinder remains static, while
the rod extends and retracts. They are specifically
designed for pick and place applications.
AIR CHUCK OR FULCRUM-TYPE GRIPPER

An actuator designed to grip components and workpieces

in robotic-type applications

Typical picture of a Pneumatic Gripper

 DOUBLE-ENDED ROD CYLINDERS

The double rod cylinder can be used to drive a long

stroking workpiece attached to the cylinder housing.
Guiding and rigidity is obtained by the piston rod ends
when they fixed on side walls thus the cylinder moves
with attached workpiece.
 TANDEM CYLINDERS

A tandem cylinder is two double acting cylinder joined

together with a common piston rod, to form a single
unit. By simultaneously pressurizing both cylinder
chambers, the output force is almost double that of a
standard cylinder of the same diameter. It offers a
higher force where installation spaces are restricted.
 MULTI-POSITION CYLINDERS
The two ends of a standard cylinder provide only t
wo fixed positions. If more than two fixed positions ar
e required, a combination of two double-acting cylinde
rs may be used.

For three positions, it is still possible to fix the cyli

nder. They are however suitable for vertical movement
s such as in handling devices.
MULTIPLE POSITION CYLINDER
• CONSIST OF AT LEAST TWO
INCORPORATED DOUBLE ACTING
CYLINDERS WITH THE BASES FACING
EACH OTHER. EACH PISTON BEING HIT
BY COMPRESSED AIR, WILL MOVE OUT.
TWO CYLINDERS PROVIDE FOUR
POSITIONS.
 LOCKING CYLINDERS

A cylinder can be fitted with a locking head

in place of the standard end cover. It will
hold the position of the rod in any position.
The locking action is mechanical ensuring
the piston rod is securely held even under
full load.
 DIFFERENTIAL CYLINDERS.

The differential cylinder has a larger piston

diameter compared to its linear counterparts.
 BELLOW CYLINDER

A bellows is a device or piece of equipment with a comp

ressible chamber with flexible sides that can be expand
ed to draw air in and compressed to force the air out.
For the bellow cylinder to inflate, the input pressure
must be greater than the trigger pressure. When the
input pressure is less than the trigger pressure, the
bellow cylinder begins to deflate and return to its initial
state. Two proximity sensors can be used to detect the
cylinder's expansion.

Bellows-type Cylinder
 VANE-TYPE ROTARY ACTUATOR

This type of cylinder also converts the compressed-air

energy into rotational or back and forth movement.

▪ Air pressure acts on a vane (flat blade mounted as part

of a set in a circle so as to rotate under the action of air
pressure) which is attached to the output shaft. The
vane is sealed against leakage by a fitted rubber seal or
elastomer coating.
▪ A special three-dimensional seal seals the stopper
against the shaft and the housing. The size of the
stopper defines the rotation angle of 90, 180 or 270
degrees. Adjustable stops may be provided to adjust
any angle of rotation of the unit.
COMPRESSED-AIR MOTOR

The compressed-air motor converts the compressed

-air energy into rotational movement. Available torqu
e for the shaft is directly proportional to the differenc
e in air pressure between the input and output ports.
The output port of a one direction motor is usually c
onnected to the exhaust and is fitted with a muffler.
SYMBOLS

FILTER

FILTER WITH WATER TRAP

FILTER WITH AUTO DRAIN

 SYMBOLS

LUBRICATOR

PRESSURE REGULATOR

FRL - AIR SERVICE UNIT

 SYMBOLS

AIR COMPRESSOR, REVERSIBLE

COMPRESSED AIR

DOUBLE ACTING CYLINDER

DOUBLE ACTING CYLINDER WITH CUSHION,

ADJUSTABLE

SINGLE ACTING CYLINDER

VALVES
 Pneumatic Valves
Pneumatic control system consists of signal components
and control components. The signal and control component
s influence the operating sequence of the working elements
and are termed valves.

It is defined in this way in DIN 24 300, following recommend

ation by CETOP (Comite Europeen des Transmissions Oleoh
ydrauliques et Pneumatiques) and ISO/R 1219-1970.

Valves are divided into 5 groups, according to their function:

1. Directional Valves (way valves)

2. Non-return valves and Logic Valves
3. Pressure control valves
4. Flow control valves
5. Shut-off valves
 DIRECTIONAL CONTROL VALVES

DEFINITION:
DIRECTIONAL CONTROL VALVES ARE DEVICES WHICH
INFLUENCE THE PATH TAKEN BY AN AIR STREAM.
FUNCTIONS:
➢ALLOWING THE PASSAGE OF AIR AND DIRECTING IT TO A
PARTICULAR AIR LINES.
➢CANCELLING AIR SIGNALS BY BLOCKING THEIR PASSAGE.
➢RELIEVING THE AIR TO ATMOSPHERE VIA EXHAUST PORT.
DIRECTIONAL CONTROL VALVES CATEGORIES

DESIGNED ARE CATEGORIZED AS:

• POPPET VALVES
➢ DISC SEAT VALVES
➢ BALL SEAT VALVES

• SLIDE VALVES
➢ LONGITUDINAL SLIDE VALVE
DIRECTIONAL CONTROL VALVES CATEGORIES

DESIGNED ARE CATEGORIZED AS:

• POPPET VALVES
➢ DISC SEAT VALVES
➢ BALL SEAT VALVES

• SLIDE VALVES
➢ LONGITUDINAL SLIDE VALVE
3/2 WAY BALL SEAT VALVE,
NORMALLY CLOSED
 3/2 WAY SLIDE (SPOOL) VALVE,
NORMALLY CLOSED AND NORMALLY OPEN
 5/2 WAY VALVE,
PUSHBUTTON & SPRING RETURN
 5/2 WAY SLIDE VALVE,
PNEUMATICALLY ACTUATED (IMPULSE)
Pilot operated 3/2 way roller valve
To avoid high actuating force, directional control valves can
be equipped with internal pilot valve & servo piston to assist
opening.
REPRESENTATION IN
DIAGRAM
REPRESENTATION IN
DIAGRAM
WHAT DOES THE DIRECTIONAL CONTROL
VALVE REPRESENT?

HOW TO READ DIRECTIONAL CONTROL

VALVE SYMBOL?
 Pneumatics _ Basic Level

2. Symbol development: Ports and Positions (ways)

Prepared by:
VENERANDO A. SISON
 Pneumatics _ Basic Level

2. Symbol development: Ports and Positions (ways)

The directional control valves is represented by the number of controlled connections,
the number of positions and the flow path.

PORTS

SWITCHING POSITION 2 /2 WAY VALVE

Prepared by:
VENERANDO A. SISON
 Pneumatics _ Basic Level

2/2 WAY VALVE

Prepared by:
VENERANDO A. SISON
 Pneumatics _ Basic Level

2/2 WAY VALVE

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VENERANDO A. SISON
 Pneumatics _ Basic Level

3/2 WAY VALVE

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 Pneumatics _ Basic Level

3/2 WAY VALVE

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VENERANDO A. SISON
 Pneumatics _ Basic Level

2. Symbol development: Ports and Positions (ways)

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VENERANDO A. SISON
 4/2 WAY VALVE

Prepared by:
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 4/2 WAY VALVE

Prepared by:
VENERANDO A. SISON
 5/2 WAY VALVE

Prepared by:
VENERANDO A. SISON
 5/2 WAY VALVE

Prepared by:
VENERANDO A. SISON
5/3 WAY VALVE
5/3 WAY VALVE
 DESIGNATION OF
DIRECTIONAL CONTROL VALVES

3/3 way DCV with a

closed-center position

4/3 way DCV with an

open-center position

5/3 way DCV with an

open-center position
 DESIGNATION OF
DIRECTIONAL CONTROL VALVES

5/3 way DCV with a

closed-center position

5/3 way DCV with a

pressurized-center
position
 Pneumatics _ Basic Level

3. Designations of pneumatic valve.

A numbering system is used to designate directional control valves and is in
accordance with DIN ISO 5599-3. Prior to this a lettering system was utilized and
both systems of designation are presented here.

Prepared by:
VENERANDO A. SISON
 PORT DESIGNATIONS
PORT DESIGNATION

LETTERS ISO 5599

INPUTS (Supply) P 1

OUTPUTS(Working Ports) A, B 4, 2

VENTS (Exhaust Ports) R, S 5, 3

PILOT (Control Ports)

Z, Y 12, 10
For 3/2 DCVs
PILOT (Control Ports)
Z, Y 14, 12
For 4/2 and 5/2 DCVs
EXAMPLES OF PORT DESIGNATIONS
 Pneumatics _ Basic Level

EXAMPLES OF PORT DESIGNATIONS

WHAT CAUSES THE VALVE TO CHANGE

POSITION?

WHAT ARE THE DIFFERENT

METHODS OF ACTUATION?

Prepared by:
VENERANDO A. SISON
 VALVE ACTUATIONS

1. Manual

2. Mechanical

3. Electrical 4. Pneumatic

5. Combinations
METHODS OF ACTUATIONS
(MANUAL)
METHODS OF ACTUATIONS
(MECHANICAL)
METHODS OF ACTUATIONS
(PNEUMATIC)
 METHODS OF ACTUATIONS
(ELECTRICAL AND COMBINATIONS)
MECHANICAL ACTUATION(ROLLER)
MECHANICAL ACTUATION(ROLLER)
 Pneumatics _ Basic Level

3/2-way valve, normally closed, ball seat

The valve connects the output signal 2 to exhaust 3
and thus to atmosphere in the initial position

Prepared by:
VENERANDO A. SISON
 Pneumatics _ Basic Level

3/2-way valve, normally closed, ball seat

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

Prepared by:
VENERANDO A. SISON
 Pneumatics _ Basic Level

3/2-way valve, normally closed, ball seat

Actuation of the valve plunger causes the ball to be

forced away from the seat

Prepared by:
VENERANDO A. SISON
 Pneumatics _ Basic Level

3/2-way valve, normally closed, ball seat

In the actuated state, connection 1 and 2 are connected
and the valve is switched to flow

Prepared by:
VENERANDO A. SISON
MANUAL ACTUATION(PUSH BUTTON)
MANUAL ACTUATION(PUSH BUTTON)
AIR ACTUATION
AIR ACTUATION
Review time
 Name the following
DIRECTIONAL CONTROL VALVES

2/2 way NC

2/2 way NO

3/2 way NC

3/2 way NO
 DESIGNATION OF
DIRECTIONAL CONTROL VALVES
4/2 way DCV (14) with a
common exhaust

4/2 way DCV (12) with a

common exhaust

5/2 way DCV (14) with

separate exhausts

5/2 way DCV (12) with

separate exhausts
 DESIGNATION OF
DIRECTIONAL CONTROL VALVES

3/3 way DCV with a

closed-center position

4/3 way DCV with an

open-center position

5/3 way DCV with an

open-center position
 DESIGNATION OF
DIRECTIONAL CONTROL VALVES

5/3 way DCV with a

closed-center position

5/3 way DCV with a

pressurized-center
position
 CONTROL OR ACTUATION METHODS OF
DIRECTIONAL CONTROL VALVES
The control or actuation methods are used to switch-over between the valves
various switching positions. They are drawn directly at the side of the square
as it represents the directional control valve’s switching position to which it
applies. The following are the common valve operators:

1.MANUAL / MUSCULAR CONTROL

• Generally obtained by attaching an operator head,

suitable for manual control, onto a mechanically-operated
valve.
• Manually-operated, monostable valves (spring return
valves) are generally used for starting, stopping and
otherwise controlling a pneumatic circuit.
• In circumstances where it is more convenient if the valve
maintains its position, manually-operated bistable valves
(with detent or impulse) should be used.
 CONTROL OR ACTUATION METHODS OF
DIRECTIONAL CONTROL VALVES

2. MECHANICAL CONTROL
• On an automated machine, these valves can detect moving
machine parts to provide signals for the automatic control of
the working cycle.

3. PNEUMATIC / PRESSURE CONTROL

• Normally, air-operated valves are the main valves which are

located close to a cylinder or other actuator, and are switched by
remote control from signal input valves or switches.

• A monostable air-piloted valve is switched by air pressure

acting on a piston and returned to its normal position by an air-
spring, mechanical spring, or a combination of both, when the
signal pressure is removed.
 CONTROL OR ACTUATION METHODS OF
DIRECTIONAL CONTROL VALVES

4. ELECTRICAL CONTROL

• The electrical operation is effected by a solenoid and a

plunger, and therefore the units are generally known as
solenoid valves.

• Direct acting solenoid valves rely on the electromagnetic

force of the solenoid valve to move a poppet or spool.

• To limit the size of the solenoid, larger valves have

indirect solenoid pilot operation.
MANUAL CONTROLS
MECHANICAL CONTROLS
PNEUMATIC CONTROLS
ELECTRICAL CONTROLS
 NAMING DIRECTIONAL CONTROL VALVES

2/2 way valve, NC,

PB actuated, spring 3/2 way reversible
5/2 way valve, air
return valve, air act, spring ret.
actuated, pilot air return

3/2 way valve, NO,

lever actuated,
detent
5/3 way valve, closed at mid position,
solenoid actuated, spring center

3/2 way valve,NC,

roller actuated, spring
return
PNEUMATIC CONTROL SYSTEM
AND SIGNAL FLOW
 Pneumatics _ Basic Level

1. Structure and signal flow of pneumatic systems.

Classification of Symbols of
Signal flow component
Prepared by: components
VENERANDO A. SISON
 Pneumatics _ Basic Level

1.Circuit diagram and pneumatic elements

Prepared by:
VENERANDO A. SISON
 MONO STABLE AND BISTABLE VALVES

BISTABLE VALVE MONO STABLE VALVE

Control Valve Spool Outlet Ports Control
Input Input

Housing Exhaust Port Pressure Inlet Exhaust Port

Port

Cross-sectional view of the component’s construction

5/2 way Pneumatic Impulse Valve

 Outlet
Electric Housing Ports
Spring
Control

Magnet Slug

Exhaust Port Exhaust Port

Pressure Inlet
Port
Cross-sectional view of the component’s construction

5/2 way Solenoid-Controlled Impulse Valve

 FLOW-CONTROL VALVES /
SPEED REGULATION VALVES /
SPEED CONTROLLER VALVES
 FLOW-CONTROL VALVES / SPEED REGULATION VALVES / SPEED
CONTROLLER VALVES

An essential advantage inherent in pneumatic control engineering is the

fact that it is an uncomplicated and inexpensive matter to adjust the working
speed of cylinders and rotary actuators, as well as the speed of air
motors. Cylinder piston rod speeds depend upon a number of factors:

• The speed restriction due to throttle valves and non-return valves with restriction.
• Mechanical conditions, load and load changes
• Flow cross-sectional areas of actuators
• Diameters of hosing and tubing and the length involved
• Amount of pressure and pressure changes in the system.
 THROTTLE VALVES

Throttle valves are members of the flow control family. Fitting an

adjustable throttle valve to reduce the cross-sectional area enables
the compressed-air flow rate to be adjusted, and with it the working
speed.
Throttle valves are connected into the line as close as possible to the
element concerned. Fixed-set throttles and throttle valves are fitted
to special-purpose sub-assemblies like pneumatic timers.
 Pneumatics _ Basic Level

Throttle valves

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 SCREW-INSERT THROTTLE VALVE

Screw-insert throttle valves are screwed directly into the

ports of the directional control valves.

2
Screw-Insert Throttle Valve
 FIXED THROTTLE VALVES

A fixed throttle valve restricts air flow. The air flow going
through a throttle valve depends on the opening percentage
and the pressure differential between the input and the output
of the valve.
At a constant opening percentage of the throttle valve, air
flow increases if the pressure differential between the
input and the output increases.

Non-Adjustable Throttle Valve

Typical Picture of an Adjustable Throttle Valve

1 2

Adjustable Throttle Valve

 REGULATING THE SPEED OF
PNEUMATIC CYLINDERS

Throttling a Single-Acting Cylinder

When the pushbutton is pressed,
pressure is applied to the piston area of
the single-acting cylinder and its piston
rod will extend at a speed slower than
normal. But when the button is
released, the piston rod will retract due
to the force of the spring and will
exhaust through the 3/2 directional
control valve’s exhaust port but at a
much slower speed as compared to
the extending motion.
 REGULATING THE SPEED OF
PNEUMATIC CYLINDERS

Throttling a Double-Acting Cylinder

When the pushbutton is pressed, pressure

is applied to the piston area of the double-
acting cylinder and its piston rod will
extend at a speed slower than normal.
But when the button is released, the piston
rod will retract and will exhaust through the
5/2 directional control valve’s exhaust port
but at a much slower speed as compared
to the extending motion.
 REGULATING THE SPEED OF
PNEUMATIC CYLINDERS

Throttling a Double-Acting Cylinder using Screw-Insert

Throttle Valves

Also, if 5/2 directional control valves

are used as actuators, screw-insert
throttle valves can be fitted at the
vent ports of the valves to adjust the
cylinder speed in each direction
independently.
 CHECK VALVE OR NON-RETURN VALVE
A non-return valve allows air to flow in one direction and seals it off in the the
opposite direction. Non-return valves are incorporated in speed controllers
such as one-way flow-control valves and in seal fittings.

1 2

Typical Picture of a Non-Return Valve Non-Return Valve

 Pneumatics _ Basic Level

Check valves

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 ONE-WAY FLOW-CONTROL VALVE / THROTTLE CHECK VALVE /
NON-RETURN VALVE WITH RESTRICTION

Typical applications of one-way flow control valves are speed control of

pneumatic cylinders in highly automated production systems in packaging,
assembly, plastics and machine tool industries.
 Regulating
Screw
Housing Spring

Port 1 Port 2

Check Valve
Cross-sectional view of the component’s construction

One-Way Flow-Control Valve

 TYPES OF RESTRICTION OR THROTTLING WITH
THROTTLE-CHECK VALVES
When the non-return valves with restriction are used, a distinction is made between
inlet-air throttling and exhaust-air throttling.

Supply-Air Throttling
of the Piston-Rod
Extension
Exhaust-Air Throttling of
the Piston-Rod Extension
 Pneumatics _ Basic Level

Quick exhaust valve

Exhaust

Outlet

Supply air

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 Pneumatics _ Basic Level

Quick exhaust valve

Exhaust

Sealing
Outlet disc

Supply air

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Quick exhaust valve
A A
P
R

P
Quick exhaust valve
A A
P
R

P
Quick exhaust valve
A A
P
R

P
Quick exhaust valve
A A
P
R

P
Quick exhaust valve
A A
P
R

P
Quick exhaust valve
A A
P
R

P
Quick exhaust valve
A A
P
R

P
Quick exhaust valve
A A
P
R

P
 SILENCERS
The sudden venting or exhaust of the
cylinder chambers generates lots of noise
especially to large-volume cylinders. As a
result of regional noise-emission
regulations, therefore, it is imperative that the
quick-exhaust valves are fitted with silencers.
The speed of the exhausted air is reduced
sharply in the interior of the silencer with the
result that the decompression noise is also
reduced. Silencers are used to diminish the Typical picture of a Silencer
noise and the carry over of particles produced
by air exhausts on the various pneumatic
components. They are installed at the exhaust
port of most valves.

Some models have a variable throttle that

can be adjusted by a screw. The restriction
at this port will control the air flow going
through the silencer so that it can slow
down the actuator from which the air
escapes.
 TWO PRESSURE VALVES/
OR “AND” VALVES

The pressure-shuttle valve is also used for logical operations using pneumatic
signals. The valve has two inlets (E1 and E2) and an outlet (A).
Since a signal shall only be present at the outlet until a signal is present at both
inlets, this valve is regarded as a Logical-AND-Valve.
The pressure-shuttle valve in itself is not to be regarded as a safety-function
valve, but only as a logical-function valve in the appropriated sub-
assemblies.
If the two applied signal pressures are unequal, it is always the lower
pressure which appears at the outlet.

Typical picture of a Two

Pressure Valve
 A

E1 E2

Cross-sectional view of the component’s construction

A1

E1 E2

Two Pressure Valve

Logical Control of a Cylinder Extension
using a Two Pressure Valve
 SHUTTLE VALVE (OR VALVE)

THE SHUTTLE VALVE PERMITS

COMPRESSED AIR TO FLOW
FROM EITHER OF THE TWO
CONNECTIONS (X OR Y) TO
A. THE BALL IN THE VALVE
ALWAYS SHUTS OFF THE
OPPOSITE CONNECTION.
SUITABLE FOR ACTUATION OR
CONTROL OF PNEUMATIC
DEVICES FROM TWO
POSITIONS.
SHUTTLE VALVES OR “OR” VALVES

Logical Control of a Cylinder Extension

using a Shuttle Valve
NON RETURN VALVES AND LOGIC VALVES,
& THEIR SYMBOLS
FLOW CONTROL VALVES
& THEIR SYMBOLS
PRESSURE SEQUENCE VALVE

THESE VALVES ARE USED FOR PRESSURE

INDUCED TRANSMISSION OF A SIGNAL FROM
P TO A.
UNLESS COMPRESSED AIR HITS THE
DIAPHRAGM, THE FLOW OF COMPRESSED AIR
FROM P IS SHUT OFF BY A BALL VALVE AND AIR
CAN FLOW FROM A TO R.
THE PRESSURE REQUIRED AT Z TO MAKE THE
PISTON MOVE THE VALVE BODY AND SHUT
OFF R DEPENDS ON THE INITIAL TENSION IN
THE DIAPHRAGM RETURN SPRING. AS THE
PISTON MOVES FORWARD, THE PUSH ROD
LIFTS THE BALL AND ADMITS FLOW OF AIR
FROM P TO A.
TIME-DELAY VALVE

CONTROL AIR FLOWS FROM Z THROUGH

THE ADJUSTABLE THROTTLE INTO THE
RESERVOIR. THE PRESSURE BUILDS UP IN
HERE AND ACTS ON THE ACTUATING PISTON.

WHEN THE PRESSURE IN THE RESERVOIR

HAS REACHED THE REQUIRED VALUE,
THE VALVE PISTON BLOCKS THE FLOW
BETWEEN A AND R, AND THE CHANNEL
FROM P TO A IS OPENED.
SAMPLE CIRCUIT
 POSITION-DEPENDENT CONTROLS

When an actuator performs a movement (for instance, the

cylinder’s piston rod moves out), and a second operation is triggered
depending upon the rod’s movement (which is monitored and signaled
back), this is referred to as Position-dependence.
Position switches or Limit switches are used to register and
signal back such movements. For the most part, 3/2 directional
control valves are used as position switches in pneumatic engineering.
These are mechanically-controlled valves with spring return. One
prerequisite for the use of such valves is that only low actuating forces
should be needed.
 Plunger

Roller
Roller

Roller with Idle Return

Roller
with Free Return
Position Switch used in Position-Dependent Controls
S1

S1

Graphical Representation of a Position Switch

 Note that the actuation of a position switch by S1 S2

means of an operating cam (machine part that

transfers motion) on the piston rod is
symbolized by a triangle.
The position of the mounting or the position- Representation of Roller with
switch actuation is symbolized by a dash. Idle Return

Note that the direction in which the actuation takes place is indicated by an arrow.
S1

No Mechanical Contact Mechanical Contact

S1 S1

Mechanical Contact Mechanical Contact

When Extending When Retracting
POSITION DEPENDENT CONTROL FOR
DOUBLE-ACTING CYLINDER
OSCILLATING MOVEMENT
CONTROL FOR MULTIPLE ACTUATORS

LIFTING DEVICE FOR BOXES

 The signal for advancing is designated using a '+'
and the signal for retracting using a '-'

The sequence is to be read

as follow :

cylinder A advances, A+
cylinder B advances, B+
cylinder A retracts, A-
cylinder B retracts. B-

A+ B+ A- B-
A+ B+ A- B-

A+ B+ A- B-
 A+ / B+ / A- / B- /
B1 A0 B0
B0 A1

PB
 A+ / B+ / A- / B- /
B1 A0 B0
B0 A1

PB
 A+ / B+ / A- / B- /
B0 A0 B0
B0 A1

PB
 A+ / B+ / A- / B- /
B0 A0 B0
B0
B0 A1
A1

PB
 A+ / B+ / A- / B- /

B0 A1 B1 A0 B0

PB

A+ A- B+ B-

B1 A1 A0
B0
ACTIVITY:

MAKE A PNEUMATIC CIRCUIT FOR THE FOLLOWING:

1. A+/ B-/ A-/ B+ -

2. B+/ A-/ B-/ A+ -

3. A-/ B+/ A+/ B- -

4. B-/ A+/ B+/ A- -

5. B+/ A+/ B-/ A- -

6. B+/ A-/ A+/ B- -

 CASCADE (TWO GROUP)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+/ B+/ Gp ll B-/ A-/
Run/End
A1 B1 B0 A0

a0 b1
 CASCADE (TWO GROUP)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+/ B+/ Gp ll B-/ A-/
Run/End
A1 B1 B0 A0

a0 b1
 CASCADE (TWO GROUP)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+/ B+/ Gp ll B-/ A-/
Run/End
A1 B1 B0 A0

a0 b1
 CASCADE (TWO GROUP)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+/ B+/ Gp ll B-/ A-/
Run/End
A1 B1 B0 A0

a0 b1
 CASCADE (TWO GROUP)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+/ B+/ Gp ll B-/ A-/
Run/End
A1 B1 B0 A0

a0 b1
 CASCADE (TWO GROUP)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence
Gp l A+/ B+/ Gp ll B-/ A-/
Run/End
A1 B1 B0 A0

a0 b1