Pneumatic system diagram for workshop applications

Lecture 12
Pneumatic stamping system
Electro Pneumatic
Pneumatic Pending Machine

Presented By

Prof. Dr. Abu Bakr I. Abdel Wahab

Helwan University
1

Draw the circuit diagram and designate the valves for a

pneumatic system with double-acting cylinder which is used to
press together glued (stamping) components.
Upon operation of a push button, the clamping cylinder extends
Once the fully advanced position is reached, the cylinder is to
remain for a time of T= 6 seconds and then immediately retract to
the initial position. The cylinder retraction is to be adjustable.
A new start cycle is only possible after the cylinder has fully
retracted

Professor Abubakr Abdelwahab

 3

Valve 1S1 and the limit switch 1S2 must be actuated as a start condition.
The limit switch 1S2 is not actuated unless the piston rod is in its initial
position.
If the start condition is fulfilled, the dual-pressure valve 1V1 (AND condition)
is switched to flow and a signal is applied at the control port y1 of the double
pilot valve 1V3.

Professor Abubakr Abdelwahab

 The valve 1V3 reverses, pressure is applied at the piston side of the cylinder
and the piston rod advances.
The advancing speed is dependent on the setting of the one-way flow control
valve 1V5 (exhaust air control).
After a short advancing travel, the piston rod releases the limit switch 1S2.

Following this, the AND condition at the dual-pressure valve 1V1 is no longer
met and the signal at the control port y1 of the double pilot valve 1V3 is reset
Despite the double pilot valve 1V3 is reset, its switching position does not
change

Professor Abubakr Abdelwahab

 A renewed actuation of the valve 1S1 is now ineffective until the system
has reached its initial status again.

When the extension physical

(stamping) position is reached,
the limit switch 1S3 is actuated.
The air reservoir in the time
delay valve 1V2 starts filling up
via the integrated one-way flow
control valve.
The rate of pressure increase is
dependent on the setting of the
integrated restrictor.

Professor Abubakr Abdelwahab

 When the pressure is sufficiently high, the 3/2-way valve switches and a signal
is applied at the control port 12 of the double pilot valve 1V3.
The valve 1V3 reverses, pressure is applied at the piston rod side of the
cylinder and the piston rod retracts.

12

When retracting, the limit switch 1V3 reverses and the air reservoir of the time
delay valve 1V2 is exhausted to atmosphere via the non-return valve and the
valve 1S3.
As result of this, the valve 1V2 switches into its initial position (Normal
position).
The signal at the double pilot valve 1V3 is then reset.

12

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Professor Abubakr Abdelwahab

 When the piston rod reaches its initial position, the limit switch 1S2 is actuated
and a new cycle can be started

11

Electro-pneumatic control

Electro-pneumatic control consists of electrical control systems

operating pneumatic power systems.

Electro pneumatics is used in many areas of Industrial

automation.

They are also used in production, assembly, pharmaceutical,

chemical and packaging systems.

Control of Electro Pneumatic system is carried out either using

combination of :
• Relays and Contactors
• Programmable Logic Controllers [PLC]

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Professor Abubakr Abdelwahab

 In Electro pneumatic controls, mainly three important steps are
involved:

Signal input devices:

Signal generation such as Switches and Contactor,
Various types of contact and proximity Sensors

Signal Processing :
Use of combination of contactors of Relay

Signal Out puts:

Used for activation of Solenoids, Indicators or Audible Alarms

13

Seven basic electrical devices

Seven basic electrical devices commonly used in the control of

fluid power systems are

1. Manually actuated push button switches

2. Limit switches
3. Pressure switches
4. Solenoids
5. Relays
6. Timers
7. Temperature switches

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Professor Abubakr Abdelwahab

 Push button switches

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Push buttons are of two types

i) Momentary push button:
Return to their unactuated position when they are released.

NO NC
ii) Maintained contact or detent push button:
Latching mechanism to hold it in the selected position

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 Make Switch

Break Switch

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Limit switches
Any switch that is actuated due to the position of a fluid power
component (usually a piston rod or hydraulic motor shaft or the
position of load) is termed as limit switch
Limit switches and proximity sensors are used as feedback
elements (Signal input devices)

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Professor Abubakr Abdelwahab

 The actuation of a limit switch provides an electrical signal that
causes an appropriate system response.

Limit switches perform the same function as push button

switches.

Push buttons are manually actuated whereas limit switches are

mechanically actuated.

19

Solenoids
Electrically actuated directional control valves
Form the interface between the two parts of an electro pneumatic
control.
Electrically actuated directional control valves are switched with
the aid of solenoids

3/2 single solenoid Valve

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 Normal positions Actuated positions

5/2 single solenoid

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Normal positions Actuated positions

5/2 Double solenoid

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 Solenoid valves.

In the rest position, the plunger closes off a small orifice

An electric current through the coil creates a magnetic field
The magnetic field exerts an upwards force on the plunger
opening the orifice

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Relay
It convert signal input from sensors and switches to output signals
It open or closes the contacts to cause the operation of the other
electric control
It detects the undesirable condition with an assigned area and
protects the system from damage
Relays are usually designated as K1, K2, and K3 etc.

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 Relays are designed to withstand surges and harsh conditions.
When a voltage is applied to the solenoid coil, an electromagnet
field results.
This causes the armature to be attracted to the coil core.
The armature actuates the relay contacts
A return spring returns the armature to its initial position when
the current to the coil is interrupted.

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Timer Or Time delay relays

Create time delay between work operations
When push button PB is pressed (ON), capacitor C is charged
through potentiometer R1 as diode D is reverse –biased.
The time taken to charge the capacitor, depends on the resistance
of the potentiometer (R1) and the capacitance(C) of the capacitor.
By adjusting the resistance of the potentiometer, the required time
delay can be set.

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 Electro pneumatic with timer or time delay relays

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Professor Abubakr Abdelwahab

 29

Design a pneumatic system diagram for workshop applications

Pneumatic bending machine is used to bend the shown steel blanks
Length L =1m, a thickness S =2mm and the lower mold opening
width V =20 mm
The bending force is calculated by the following formulas:

S2 L
F  1.42 b
V

F: bending force, KN;

S: Sheet thickness, mm;
L : Sheet bending length, m;
V: Lower opening width, mm;
σb : Material tensile strength, MPa.

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Professor Abubakr Abdelwahab

 The Pneumatic bending machine would satisfy the following
requirements:
1. When the workpiece reaches the specified position (a2), and if the
start button is pressed, the cylinder extends to bend the
workpiece
2. When the press (arrival position a1), then quickly return,
complete one work cycle
3. If the workpiece does not reach the specified position (a2), the
cylinder does not operate even if the button is pressed.

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Professor Abubakr Abdelwahab

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Bending machine pneumatic system working principle

1-Air source
2-Pneumatic triplex – FRL - Filter-Regulator + Lubricator
3- Two-position three-way tee manual reversing valve
4-Double pressure valve
5-Quick exhaust valve
6-Double acting single piston rod cylinder
7- Two-position five-way air control reversing valve
8, 9- Two-position three-way motorized reversing valve
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Professor Abubakr Abdelwahab

 How it work?
Bending machine pneumatic system working principle
1- When the sheet moves to the a2 position, it press ….
Valve 9

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Professor Abubakr Abdelwahab

 2- Press valve 3, ….
The compressed air enters the double pressure valve 4 (AND)
through the valve 3 and the valve 9

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3- The compressed air then change the valve 7 position to the left
position. The compressed air enter the cylinder through the valve 5,

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Professor Abubakr Abdelwahab

 4-The piston is extended
The sheet material is bent
Physical position a1 (Limit switch) is pressed
Valve 8 is opened
Valve 9 is closed

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5- The compressed air then change the valve 7 position to the right position.

The compressed air enter the cylinder rod chamber through valve 7

The air in the piston head chamber discharged through the quick exhaust
port of the valve 5, and the piston is quickly retracted.

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Professor Abubakr Abdelwahab

 a1

41

Compressor Pressure:
Find the compressor outlet pressure in KPa. The actuator has a bore diameter
of 200 mm. and rod diameter is 100 mm.
Pressure drop across the quick exhaust valve = 100 Pa .
Pressure drop across the DCV = 150 Pa
Pressure drop across the Pneumatic triplex = 250 Pa a2 a1

S2 L
F  1.42 b
V

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Professor Abubakr Abdelwahab

 Design consideration of hydraulic cylinders
Fh - Fr – FL = 0
Fh : Head pressure force S2 L
Fr : Back/Rod pressure force F  1.42  b  ..A..
Ff : Friction force V
Fg : Gravity of piston and rod
π π
Pa * * (0.2)2 - Pb * * [ (0.2)2 - (0.1)2 ] – A= 0
𝟒 𝟒
π π
Pa * * (0.2)2 - 150 * * [ (0.2)2- (0.1)2 ] – A = 0
𝟒 𝟒
Pa = ….B…. Pa
P compressor = ..B… + Pressure drop across the quick exhaust valve +
Pressure drop across the DCV + Pressure drop across the Pneumatic triplex=
P compressor = ….C… Pa

43

Calculate the 𝐏𝐫𝐨𝐝𝐮𝐜𝐭𝐢𝐨𝐧 𝐫𝐚𝐭𝐞 𝐩𝐞𝐫 𝐡𝐫 of the bending machine

If the air flow applied to the cylinder was 5 m3 per minute
The cylinder had a 500 mm stroke
Bore diameter of 200 mm. and rod diameter is 100 mm a2 a1

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Professor Abubakr Abdelwahab

 Flow applied to the cylinder was 5 m3 per minute
Cylinder had a 500 mm stroke
Bore diameter of 200 mm. and rod diameter is 100 mm

Flow rate 5 m3/min

Velocity of extension stroke = = 𝝅 = ..D.. m/s
Area 𝟒
𝟎.𝟐 𝟐
∗ 𝟔𝟎 𝒔𝒆𝒄/𝒎𝒊𝒏

Stroke length
Time of extension stroke = = …E.. Second
Velocity of the piston

Flow rate 5 m3/min

Velocity of retraction stroke = = 𝝅 = …F… m/s
Area 𝟒
[ 𝟎.𝟐 𝟐
− 𝟎.𝟏 𝟐]

Stroke length
Time of retraction stroke = = …G…. Second
Velocity of the piston

Time of One cycle = ……F…+ …G….. = …H…… Sec.

𝟏 𝒉𝒓
𝐏𝐫𝐨𝐝𝐮𝐜𝐭𝐢𝐨𝐧 𝐫𝐚𝐭𝐞 𝐩𝐞𝐫 𝐡𝐫. = = ……I…
Time of One cycle.
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Application :

Think about a proposal for the application of the following

system and explain how it work?

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Professor Abubakr Abdelwahab

 .

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Professor Abubakr Abdelwahab