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Pneumatic
system
design

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Pneumatics Applications
Automobile:

Automobile industry use pneumatic systems for:-

ü dismantling vehicle tire,

ü filling compressed air in the tire,

ü vehicle painting,

ü opening and closing of doors,

ü Automobile production lines

ü air brakes on heavy vehicles, etc

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Pneumatics Applications

air brakes on heavy vehicles

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Pneumatics Applications

üfilling compressed air in the tire,

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Pneumatics Applications
• Automobile production lines

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Pneumatics Applications

vehicle painting

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Pneumatics Applications

Reveter for brake linig and shoe

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Pneumatics Applications
Transport system
When the button switch is pushed, the cylinder will push one of the goods from
the shelf onto the transfer belt. When the button switch is released, the cylinder
will retract automatically.

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Pneumatics Applications
opening and closing of doors

Pneumatic systems can be used to

operate the doors of public vehicles

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Pneumatics Applications

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Pneumatics Applications

• Industrial Applications:
üMaterial handling,
üdrilling,
üfilling,
üpackaging,
üclamping,
üshifting, etc. are some of the general applications of the
pneumatic system.

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Advantages of pneumatic systems

High effectiveness
Many factories have equipped their production lines with compressed air
supplies and movable compressors. There is an unlimited supply of air in our
atmosphere to produce compressed air.
Moreover, the use of compressed air is not restricted by distance, as it can easily
be transported through pipes.
After use, compressed air can be released directly into the atmosphere without
the need of processing.

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Advantages of pneumatic systems

Small weight of transmission lines due to;

• The small diameter of lines.

• The low density of energy transmitting fluid; the air.

• There are no return lines; used air is expelled into the

atmosphere.

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Advantages of pneumatic systems

High durability and reliability

• Pneumatic components are extremely durable and can not be damaged

easily. Compared to electromotive components, pneumatic
components are more durable and reliable.

Simple design

• The designs of pneumatic components are relatively simple. They are

thus more suitable for use in simple automatic control systems.

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Advantages of pneumatic systems

High adaptability to harsh environment
Compared to the elements of other systems, compressed air is less affected
by high temperature, dust, corrosion, etc.
Safety
Pneumatic systems are safer than electromotive systems because they can
work in inflammable environment without causing fire or explosion.
Apart from that, overloading in pneumatic system will only lead to sliding
or cessation of operation. Unlike electromotive components, pneumatic
components do not burn or get overheated when overloaded.

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Advantages of pneumatic systems

Easy selection of speed and pressure
The speeds of rectilinear and oscillating movement of pneumatic systems are easy to adjust
and subject to few limitations. The pressure and the volume of air can easily be adjusted by a
pressure regulator.
Environmental friendly
The operation of pneumatic systems do not produce pollutants. The air released is also
processed in special ways. Therefore, pneumatic systems can work in environments that
demand high level of cleanliness. One example is the production lines of integrated circuits.

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Advantages of pneumatic systems

• Availability of the energy transmission fluid, the air.

• The system is fireproof.

• Pneumatic systems are able to supply a great amount of energy during a short
time period, from the compressed air reservoir.

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Advantages of pneumatic systems

Economical
As pneumatic components are not expensive, the costs of pneumatic systems are
quite low.
Moreover, as pneumatic systems are very durable, the cost of repair is
significantly lower than that of other systems and also air is fee free .

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Limitations of pneumatic systems

Relatively low accuracy
As pneumatic systems are powered by the force provided by compressed air,
their operation is subject to the volume of the compressed air. As the volume of
air may change when compressed or heated, the supply of air to the system may
not be accurate, causing a decrease in the overall accuracy of the system.
Low loading
As the cylinders of pneumatic components are not very large, a pneumatic
system cannot drive loads that are too heavy
i.e it act small load to components as compared to hydraulic system.

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Limitations of pneumatic systems

Processing required before use
Compressed air must be processed before use to ensure the absence of water vapour or
dust.
Otherwise, the moving parts of the pneumatic components may wear out quickly due to
friction so that there must be lubricator.
Uneven moving speed
As air can easily be compressed, the moving speeds of the pistons are relatively uneven.
Noise
Noise will be produced when compressed air is released from the pneumatic components.

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Limitations of pneumatic systems

• Difficult system tightness.
• Low working pressure compared with the hydraulic systems due to the tightness problems and
compressor design (within 10 bar for industrial systems and more than 200 bar for aerospace
systems).
• Difficulty of holding pneumatic actuators at intermediate positions.
• Delay of actuators’ response due to the time needed for filling the long lines with compressed air.
• The variation of pressure in air reservoirs with temperature.
• The possibility of the condensation of humidity and the freezing of condensed water at low
temperatures.
• Special lubricators are needed due to the poor lubricity of air.

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Principles of pneumatic control

Pneumatic control systems can be designed in the form of pneumatic circuits.

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.

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A circuit diagram is usually divided into three levels: power level,

logic level and signal input level

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Different kinds of basic circuits

• A basic circuit is a pneumatic circuit designed to perform basic tasks, such as
flow amplification, signal inversion, memory, delay, single acting cylinder
control, double acting cylinder control, etc.

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Different kinds of basic circuits

Flow amplification
Cylinders with a large capacity require a larger flow of air, which can be hazardous
to users. It is unsafe to manually operate pneumatic directional control valves with
large flow capacity.
Instead we should first operate manually a small control valve and use it to operate
the pneumatic control system with large flow capacity. This is called flow
amplification, which can greatly ensure the safety of the operators.
During operation, valves with large flow capacity should be placed near the
cylinder, while valves with smaller flow capacity should be placed on control
boards some distances away.
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Different kinds of basic circuits

Flow amplification

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Different kinds of basic circuits

Signal inversion
The pneumatic diagram in Fig. shows how directional control valves
can be switched.

When operating control valve 1, control valve 2 will stop producing

pressure output. When control valve 1 ceases operation and is
restored to its original position, control valve 2 will resume its
output. Therefore, at any given time, the pressure output of control
valve 1 is the exact opposite of that of control valve 2.

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Different kinds of basic circuits

Memory Function

Memory is a common basic function. It can keep a component at

a certain state permanently until there is a change of signals. Fig.
25 shows a memory function circuit. When control valve 1 is
operated momentarily (that is, pressed for a short time), the output
signal of the 5/2 directional control valve 3 will be set to ON.
The signal will stay that way until control valve 2 is operated
momentarily and generates another signal to replace it, causing it to
stay permanently at OFF.

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Different kinds of basic circuits

Delay function
A pneumatic delay circuit can delay the operating time of the next control valve.
Its principle of operation involves the use of an orifice to slow down the flow
of air and control the time of pneumatic operation.
Delay functions can be divided into two classes: ON-signal delay and OFF
signal delay

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Different kinds of basic circuits

Delay function
ON-signal delay

Fig. shows the circuit diagram of an ON-signal delay circuit, which

delays the output of the next control valve. When control valve 1 is
operated, the one way flow control valve will slow down the flow of
air, thus delaying the signal output of the outlet of control valve 2
(A), resulting in a persistent ON-signal. The time when control valve
2 will be restored to its original position is not affected.

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Different kinds of basic circuits

Delay function
OFF-signal Delay
Fig. shows the circuit diagram of an OFF-signal delay circuit,
which delays the output of the next control valve. This circuit
is similar to an ON-signal delay circuit. The only difference is
that the one way flow control valve is connected in the
opposite direction. Therefore, when control valve 1 is
operated, the outlet of control valve 2 (A) will continue to
output signals. However, when control valve 2 is restored to
its original position, the release of air is slowed down by the
one way flow control valve, resulting in a persistent OFF-
signal.
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Pneumatic controller
• A controller is a comparative device that receives an input signal from a
measured process variable, compares this value with that of a predetermined
control point value (set point), and determines the appropriate amount of
output signal required by the final control element to provide corrective action
within a control loop.
• A Pneumatic Controller is a mechanical device designed to measure
temperature or pressure and transmit a corrective air signal to the final control
element.
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Pneumatic controller
Advantages of pneumatic controllers
• Simplicity of the components and no complex structure
• Easy maintainability
• Safe and can be used in hazardous atmospheres
• Low cost of installation
• Good reliability and reproducibility
• Speed of response is relatively slow but steady

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Pneumatic controller
Limitations of pneumatic controllers
• Slow response
• Difficult to operate in sub-normal temperatures
• Pipe-couplings can give rise to leaks in certain ambient
conditions
• Moving parts - more maintenance

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OPEN-LOOP CONTROL
• Open-loop control systems do not possess feedback

The principal features of open-loop control systems are:

• They are simple
• Their accuracy is determined by the calibration of their elements
• They are not generally troubled with instability.

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CLOSED-LOOP CONTROL
• A closed loop control system is a mechanical or electronic device that automatically
regulates a system to maintain a desired state or set point without human interaction.

• The Closed Loop is a control option to prevent the inlet of outside atmosphere into the
actuator pneumatic cylinder.
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CLOSED-LOOP CONTROL

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CLOSED-LOOP CONTROL
The principal features of closed-loop control systems are:
• they are highly accurate
• they are more complex
• non-linearities and distortion are greatly reduced
• they have wide bandwidth of operation
• they suffer from instability problems.

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Pneumatic circuit design consideration

When analyzing or designing a pneumatic circuits, the following four
important considerations must be taken into account:
• Safety of operation

• Performance of desired functions

• Efficiency of operation

• Costs

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Pneumatic circuit design

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Air Capacity Rating of Compressors

• Air compressors are generally rated in terms of cfm of free air, defined as air at actual
atmospheric conditions.
• CFM is an acronym for Cubic Feet per Minute. It measures the volume of air, in cubic feet, for
each minute it moves.
• Cfm of free air is called scfm when the compressor inlet air is at the standard atmospheric
conditions of 14.7 psi and 68°F.
• Therefore, a calculation is necessary to determine the compressor capacity in terms of cfm of
free air or scfm for a given application.
• In metric units a similar calculation is made using m3/min of free air or standard m3/min
where standard atmospheric conditions are 101,000 Pa abs and 20°C.
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Air Capacity Rating of Compressors

• The equation that allows for this calculation is derived by solving the general gas law Eq. for
V1 as follows:

• subscript 1 represents compressor inlet atmospheric conditions (standard or actual) and

• subscript 2 represents compressor discharge conditions.
• Dividing both sides of this equation by time (t) converts volumes V1 and V2 into volume flow
rates Q1 and Q2, respectively.
Thus, we have the desired equation:

NB; Temperature scale→Rankine for english unit

→Kelvin for metric units
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Example
1. Air is used at a rate of 30 cfm from a receiver at 90°F and 125 psig. If the
atmospheric pressure is 14.7 psia and the atmospheric temperature is 70°F, how many
cfm of free air must to compressor provide?

°R = °F + 459.67

In other words, the compressor must receive atmospheric air (14.7 psia and 70°F) at a rate
of 275 cfm in order to deliver air (125 psi and 90°F) at 30 cfm.

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Example

2. Air is used at a rate of 1.0 m3/min from a receiver at 40°C and 1000
kPa gage. If the atmospheric pressure is 101 kPa abs and the atmospheric
temperature is 20°C, how many m3/min of free air must to compressor
provide?

Kelvin = Celsius + 273.15

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Sizing of Air Receivers

case 1; Air is supplied to the receiver during the time interval in which air is
being drawn off
In such cases we can find the capacity of receiver as
where
t = time that receiver can supply required amount of air (min),
Qr = consumption rate of pneumatic system (scfm, standard m3/min),
Qc = output flow rate of compressor (scfm, standard m3/min)
Pmax = maximum pressure level in receiver (psi, kPa),
Pmin = minimum pressure level in receiver (psi, kPa),
Vr = receiver size (ft3, m3).

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Sizing of Air Receivers

• Case 2 No air is supplied to the receiver during the time interval in which
air is being drawn off
i.e before the compressor resumes operation

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Example;
a. Calculate the required size of the recver that must supply air to pneumatic
system consuming 0.850m3/min for 10 minutes between 828kPa and 690Kpa
before the compressor resumes operation
b. what size is required if the compressor is running and delivering at
0.170m3/min
Solution:
The air receiver size can be determined by using the following equation
a

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EX.
a. Calculate the required size of a receiver that must supply air to a pneumatic
system consuming 20 scfm for 6 min between 100 and 80 psi beforethe
compressor resumes operation.
b. What size is required if the compressor is running and delivering air at 5 scfm?

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Cylinder Force, Velocity and Power

The output force (F) and piston velocity (V) of double acting cylinders are
not the same for extension and retraction strokes.
During the extension stroke, fluid enters the blank end of the cylinder through
the entire circular area of the piston (Ap).

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Cylinder Force, Velocity and Power

• However, during the retraction stroke, fluid enters the rod end through the
smaller annular area between the rod and cylinder bore (Ap - Ar), where Ap
equals the piston area and Ar equals the rod area.

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