Pneumatic Systems

& Circuits Design

Asst. Prof. Dr. Maher Yahya Salloom

 Transmission unit “Hydraulic & Pneumatic systems”

Pressure Pressure
Input Power (p1) Output Output Power
Input Control (p2)
Transmission Transmission
Unit
Torque Unit Flow rate Flow rate Unit
(Q1) (Q2) 1-Forces.
(T) and
the 2-Velocity.
Rotational 1- Hydraulic 1- Hydraulic & pneumatic 1 – Hydraulic 3-Acceleration.
speed Pumps. valves. cylinders .
4-Torque.
(N) 2-Air compressor. a- Directional control valves. 2- Hydraulic 5- Rotational
b- Pressure control valves. motors. speed.
c- Flow control valves. 3- Pneumatic
d- Check valves. cylinders .
2- Proportional control 4- Pneumatic
valves. motors .
3- Servo control valves.
 Pneumatic Power
Pneumatics
The use of a gas flowing under pressure to transmit power
from one location to another
Gas in a pneumatic system behaves like a spring since it is
compressible.
 Pneumatics vs. Hydraulics
Pneumatic Systems . . .
Use a compressible fluid (gases)
Possess a quicker, jumpier motion
Are not as precise
Require a lubricant
Are generally cleaner
Often operate at pressures around 8 bar
Generally produce less power
 Perfect Gas Laws
The perfect gas laws describe the behavior
of pneumatic systems
Boyle’s Law

Charles’ Law

Gay-Lussac’s Law
 Boyle’s Law

The volume of a gas at constant temperature Symbol Definition Example

Unit
varies inversely with the pressure exerted on it. V Volume cm3
p Absolut bar
p1 (V1) = p2 (V2) pressure

(absolute pressure = gage pressure + 1)

 Boyle’s Law Example
A cylinder is filled with 650 cm3 of air at a pressure of 4 bar . The
cylinder is compressed to 150 cm3. What is the resulting absolute
pressure?
p1 = 4 bar ( 4 kg/ cm3) V1 = 650 cm3
p2 = ? V2 = 150 cm3
Convert p1 to absolute pressure.
p1 = 4 bar + 1 bar = 5 bar

5 kg/ cm3 x 650 cm3 = p2 x 150 cm3

Final p2 = 21.666 kg/ cm3

 Charles’ Law
Volume of gas increases or decreases as the
temperature increases or decreases, provided the
amount of gas and pressure remain constant.

Note: T1 and T2 refer to absolute temperature.

( T °C +273.15 = T °K )
 Charles' Law Example
An expandable container is filled
with 130cm3 of air and is sitting in
ice water that is 25°C. The
container is removed from the icy
water and is heated to 175°C.
What is the resulting volume?
V1 = 130cm3
V2 = ?
T1 = 25°C
T2 = 175°C
Convert T to absolute temperature.
T1 = 25°C + 273.15°C = 298.15°K
T2 = 175°C + 273.15°C = 448.15°K
 Charles' Law Example

130 / 298.15 = V2 / 448.15

V2 = 130 * 448.15 / 298.15

V2 = 195.4 cm3
 Gay-Lussac’s Law
Absolute pressure of a gas increases
or decreases as the temperature
increases or decreases, provided the
amount of gas and the volume remain
constant.

Note: T1 and T2 refer to absolute

temperature.
p1 and p2 refer to absolute
pressure.
 Gay-Lussac’s Law Example
A 4920 cm3 sealed air tank is sitting outside. In the morning the temperature
inside the tank is 22°C, and the pressure gauge reads 8 kgf/cm2. By
afternoon the temperature inside the tank is expected to be close to 45°C.
What will the absolute pressure be at that point?

V = 4920cm3 T1 = 22°C
p1 = 8 bar T2 = 45°C
p2 = ?
Convert p to absolute pressure.
9 / 295.15 = p2 / 318.15
the absolute pressure
p1= 8 kgf/cm2 + 1 kgf/cm2
P2 = 9.7 kgf/cm2
= 9 kgf/cm2
Convert T to absolute temperature. Pressure reading at the gauge
9.7 kgf/cm2 – 1 kgf/cm2
T1 = 22°C + 273.15°C = 295.15°K
T2 = 45°C + 273.15°C = 318.15°K = 8.7 kgf/cm2
 General Gas law
Combination of the mentioned laws results is
general law as
 Pascal’s Law
Pressure exerted by a confined fluid acts undiminished equally in all
directions.
Pressure: The force per unit area exerted by a fluid against a surface

Symbol Definition Example Unit

p Pressure kgf/cm2

F Force kgf (10N)

A Area cm2
Bernoulli’s equation
equation resulting from applying conservation of energy to an
incompressible frictionless fluid:
p+1/2ρv2+ρgh = constant,
throughout the fluid

Bernoulli’s principle
Bernoulli’s equation applied at constant depth:
p1+1/2ρv21=p2+1/2ρv22
The usefulness of using compressed air as a power source is as:
1. Cleanness
2. Pressure is transmitted
undiminished in all
direction throughout the
system
3. Low cost
4. The best solution for
the jig and fixture
systems, automation
lines, pick and place in
light industry.
However, a typical maximum pressure for the pneumatic
systems is 7 to 10 bars. This indicates that the pneumatic
systems aren't suitable for the heavy duty in terms of load.
 Common Pneumatic System Components

Transmission
Lines
Pressure Pressure
Regulator Regulator

Filter
Drain Air lubricator

Receiver Tank
Directional
Control Valve

Cylinder

Pressure Relief Compressor

Valve
 Pneumatics Components
Compressor
A compressor is a machine that
compresses air or another type of
gas from a low inlet pressure (usually
atmospheric) to a higher desired
pressure level. This is accomplished
by reducing the volume of the gas.
Air compressors are generally
positive displacement units and are
either of the reciprocating piston type
or the rotary screw or rotary vane
types.
Types of compressor
Positive displacement

Non-positive displacement

Rotary centrifuge Axial compressors

Reciprocating Piston Compressor
Rotary Screw Compressor
Rotary Vane Compressor
Lobe Compressor
Rotary centrifuge and axial compressors
Selection of Compressor
It is vital for the effective and efficient running of a compressed air
plant that the appropriate compressor is selected to meet the
system needs. Large compressor installation can be expensive and
complex. However, the following points should be considered:
SYSTEM FLOWRATE DEMAND: This should include both the
estimated initial loading and near term loading.
STANDBY CAPACITY FOR EMERGINSIS: This could be a
second compressor that is connected to the main line.
FUTURE AIR REQURIMENT: This issue should be considered
in the selection of the compressor due to the cost of replacement of
the compressor.
Air capacity rating of compressors
Air compressors are generally rated in terms of (m3/min) of
free air, defined as air at actual atmospheric conditions. The
equation that allows for this calculation is

In the last equation, 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) will give us:
Sizing of Air reservoirs

The sizing of air reservoirs requires taking into account

parameters such as system pressure and flow-rate
requirements, compressor output capability, and the type of
duty of operation. It also serves to dampen pressure pulses
either coming from the compressor or the pneumatic system
during valve shifting and component operation.
The reservoirs are equipped with a safety relief valve in
order to prevent the explosion of tank.
safety relief valve
The last equation can be used to determine the proper size
of the reservoir in metrics as

Metric units

Where
t = time that reservoir can supply required amount of air (min)
Qr = consumption rate of pneumatic system (m3/min)
Qc = output flow-rate of compressor (m3/min)
Pmax= maximum pressure level in reservoir (kPa)
Pmin= minimum pressure level in reservoir (kPa)
Vr = reservoir size (m3)
Power required to drive compressors

The following equation can be used to determine the

theoretical power required to drive an air compressor.

pin = inlet atmospheric pressure (kPa abs)

pout = outlet atmospheric pressure (kPa abs)
Q = flow-rate (standard m3/min)
Air Conditioners
Air Filters
The air needs to be filtered to be free of moisture and
contamination. An air filter is used to do this job. The filter
elements remove the particles and moisture as small as 5
microns.

Symbols
 Compressed air preparation
Filtration

Symbols
Air pressure regulator
The pressure regulator is used to adjust
the desired pressure for the pneumatic
system. This use a piston to sense
downstream pressure fluctuations. The
piston, in turn, works against a set
Symbols
spring pressure. As the pressure
downstream drops it is sensed by the
diaphragm and the popper valve opens.
This adjusts the position of the poppet
valve, which limits the downstream
pressure to the pre-set valve.
Pressure control

Symbols
Air lubricator
A lubricator ensures proper lubrication of internal moving parts
pneumatics components. The proportional increase in oil mist
by an increase of air flow is achieved by the spring loaded
poppet assembly. As the flow increases and the valve opens,
the area is increased and a pressure differential created.

Symbols
Lubrication

Symbols
Air service unit
Filters, regulators and lubricators can be combined to ensure
optimum compressed air preparation for a specific pneumatic
system.

Symbols
Air preparation unit
Symbols
Pneumatic Silencer

To decrease the noise of air in the outlet of valves, a silencer

can be used. They are made from the porous plastic or
bronze. Some of them are equipped with a control flow valve
to control velocity of flow in the outlet of valves as well.

Symbols
Pneumatic Valves
The pneumatic valves are similar to hydraulic valves in terms
of physical concepts. They are categorized into three classes:
 Non –Return valves

• To allow air flow in

one direction, and the
other direction can not
because closed by
spring
Pneumatic directional control valves
 Spool Types
• A spool has a number of
major and minor diameters
called lands and valleys
• The lands seal with the valve
bore and the valleys connect
valve ports to control flow
direction
• Dynamic seal type has the
seals on the spool
• Glandless type have no
sliding seals
• Static seal type has the seals
fixed in the valve bore
 Spool Valve (dynamic seals)
• This 5/2 valve has a spool fitted with disc seals
• The seals move with the spool therefore they are called
dynamic
• Normal position: port 1 is joined to 4 and 2 is joined to 3
• Operated position: port 1 is joined to 2 and 4 is joined to 5

4 2
14 12

1
5 3

14 12
5 4 1 2 3
 Spool Valve (dynamic seals)
• This 5/2 valve has a spool fitted with disc seals
• The seals move with the spool therefore they are called
dynamic
• Normal position: port 1 is joined to 4 and 2 is joined to 3
• Operated position: port 1 is joined to 2 and 4 is joined to 5

4 2
14 12

1
5 3

14 12
5 4 1 2 3
 Actuator Control (3/2 valve)
• A 3 port valve provides the
inlet, outlet and exhaust path
and is the normal choice for
control of a single acting
cylinder
• In the normal position
produced by the spring, the 2
valve is closed 12 10

• In the operated position 3 1

produced by the push button
the valve is open
• The push button must be
held down for as long as the
cylinder is outstroked
 Actuator Control (3/2 valve)
• A 3 port valve provides the
inlet, outlet and exhaust path
and is the normal choice for
control of a single acting
cylinder
• In the normal position
produced by the spring, the 2
valve is closed 12 10

• In the operated position 3 1

produced by the push button
the valve is open
• The push button must be
held down for as long as the
cylinder is outstroked
 Actuator Control (5/2 valve)
• A five port valve provides an
inlet port 1 that is switched
between two outlet ports 2
and 4 each with an exhaust
port 3 & 5
• In the normal position
produced by the spring 1 is 4 2
connected to 2 with 4 to 14 12
exhaust 5
5 1 3
• In the operated position
produced by pushing the
button port 1 is connected to
4 with 2 to exhaust 3
 Actuator Control (5/2 valve)
• A five port valve provides an
inlet port 1 that is switched
between two outlet ports 2
and 4 each with an exhaust
port 3 & 5
• In the normal position
produced by the spring 1 is 4 2
connected to 2 with 4 to 14 12
exhaust 5
5 1 3
• In the operated position
produced by pushing the
button port 1 is connected to
4 with 2 to exhaust 3
 Principle of operation 2

3 1
3
• The double poppet armature is
held by a spring against the
inlet orifice sealing the supply
at port 1
• Outlet port 2 is connected to
exhaust port 3
• When the coil is energised the
armature is pulled up closing
the exhaust orifice and
connecting the supply port 1 to
2 1
the outlet port 2
 Principle of operation 2

3 1
3
• The double poppet armature is
held by a spring against the
inlet orifice sealing the supply
at port 1
• Outlet port 2 is connected to
exhaust port 3
• When the coil is energised the
armature is pulled up closing
the exhaust orifice and
connecting the supply port 1 to
the outlet port 2
2 1
 Type
• Type refers to the valves
installation arrangement for
example sub-base, manifold, in
line, and valve island
 Design
• Design refers to the principle of
operation around which the
valve has been designed, for
example, spool valve, poppet
valve and plate valve
 Operators
• An operator is the mechanism
that causes a valve to change Push Shrouded Mushroom Twist
state Button Button Button

• They are classified as manual,

mechanical and electrical

Switch Key Key Plunger Roller

Emergency
Released Operated
Stop

One Way Air Pilot Solenoid

Tip Pilot
Symbols
 Logic “OR” Shuttle Valve
2
• An air signal given to either the
2 1 1
left hand port 1 or the right
hand port 1 will result in an
output at port 2
• The sealing disc moves across
to seal the exhaust signal line 1 1
to prevent loss of signal 2
pressure

1 1
 Logic “AND” Shuttle Valve
2 2
• A single air signal at either of
the ports 1 will cause the 1 1 1 1

shuttle to move and block the ISO 1219-1 Popular old

symbol symbol
signal
• If a signals are applied at 2 2
both the left hand AND right
hand ports 1 only one of
them will be blocked the 1 1 1 1
other will be given as an 2 2
output at port 2
• If the pressures are not equal 1 1 1 1
the one with the lowest
pressure is switched
 Pressure Switch (pneumatic)
• Relay to boost weak signals 12
2
10
• Relay for a pneumatic time 3 1
delay
• When the signal at port 12 12
2
10
reaches about 50% of the
3 1
supply pressure at port 1,
the pressure switch
operates to give a strong
output signal at 2
• For time delays at any
pressure only the linear part 12 10
of the curve will be used
giving smooth adjustment 3 1
Pressure Switches
• Pressure applied at port 1 12
2
10
acting on the differential
3 1
annular areas holds the spool
to the left
• The weak or slowly rising
pressure of a signal applied to
port 12 needs only to reach 3
about 50% of he pressure at
port 1 to operate the valve
12 1 2

• Port 1 is then connected to port

2
• Removing the signal allows the
differential force to reset the
valve
Pressure Switches
• Pressure applied at port 1 12
2
10
acting on the differential
3 1
annular areas holds the spool
to the left
• The weak or slowly rising
pressure of a signal applied to
port 12 needs only to reach 3
about 50% of he pressure at
port 1 to operate the valve
12 1 2

• Port 1 is then connected to port

2
• Removing the signal allows the
differential force to reset the
valve
 Pressure Switches (electrical)
• This fixed value example uses Fixed
a built in single acting cylinder
to operate a standard
Adjustable
changeover microswitch
• The operating pressure is
about 3 bar this needs to
overcome the combined force
of the cylinder and microswitch
springs
• Adjustable pressure switches
are also available
Sequence valve
This type of valve operate when the pressure is high.
 Flow Regulator
• Uni-directional, line mounted
adjustable flow regulator
• Free flow in one direction
• Adjustable restricted flow in
the other direction
 Flow Regulation
• By the use of flow regulators
the outstroke speed and
instroke speed of a piston rod
can be independently
adjusted
• Speed is regulated by
controlling the flow of air to
exhaust
• The front port regulator
controls the outstroke speed
and the rear port regulator
controls the instroke speed
Quick Exhaust Valve
• In some applications cylinder
speed can be increased by
50% when using a quick
exhaust valve
• When operated, air from the
front of the cylinder exhausts
directly through the quick
exhaust valve
• The faster exhaust gives a
lower back pressure in the
cylinder therefore a higher
pressure differential to drive out
the piston rod
 Quick Exhaust Valve
• Port 2 is connected directly to 2
1
the end cover of a cylinder
• Port 1 receives air from the
control valve 2

• Air flows past the lips of the

seal to drive the cylinder
• When the control valve is
exhausted, the seal flips to the
right opening the large direct
1
flow path
• Air is exhausted very rapidly
from the cylinder for increased
speed
 Quick Exhaust Valve
• Port 2 is connected directly to 2
1
the end cover of a cylinder
• Port 1 receives air from the
control valve 2

• Air flows past the lips of the

seal to drive the cylinder
• When the control valve is
exhausted, the seal flips to the
right opening the large direct
1
flow path
• Air is exhausted very rapidly
from the cylinder for increased
speed
 Speed control applications
• The maximum natural speed of a cylinder is
determined by:
• the cylinder size,
• the ports size,
• inlet and exhaust valve flow,
• the air pressure,
• the bore and length of the hoses,
• the load against which the cylinder is working.
• From the natural speed it is
possible to increase or reduce restricted aperture
it.
• Normally a smaller valve
reduces cylinder speed.
• A larger valve might increase
cylinder speed.
• A limiting factor will be the
aperture in the cylinder ports

unrestricted aperture
• Once a valve, cylinder,
pressure and load are
selected, adjustable
speed control is effected
with flow regulators.
• Speed is regulated by
controlling the flow of air
to exhaust
• The front port regulator
controls the outstroke
speed and the rear port
regulator controls the
instroke speed.
Increasing speed
• In some applications cylinder
speed can be increased by
50% when using a quick
exhaust valve.
• When operated, air from the
front of the cylinder exhausts
directly through the quick
exhaust valve.
• Built in cushioning will be less
effective.
Pneumatic actuators
Pneumatic cylinders
The cylinders converts the energy of the compressed air into
linear motion which extend or retract the piston rod.

Symbols
 Basic Construction
1 cushion seal
2 magnet
3 cushion sleeve
4 barrel
5 guide bush
6 rod and wiper seal
7 front end cover
8 front port
9 reed switch
10 piston rod
11 wear ring
12 piston seal
13 rear end cover
14 cushion screw
Pneumatic Rotary Actuators

The rotary actuators converts the energy into a rotary motion.

Most of them is Vane air motor.

Symbols
Pneumatic Semi-Rotary Actuators
Limited rotary motion can be achieved by incorporating a
rack and pinion into a linear actuator or as seen opposite by
a Vane Mechanism within the body of the cylinder.

Symbols
Rotary pneumatic cylinder Multi-position pneumatic cylinder
Rodless pneumatic cylinder
Air motors

• Vane type
• Piston type
Sequence of Operation:
1) The directional control valve is shifted by the pilot or solenoid signal.
This causes the locking cylinder to retract, unlocking the table. Note:
The signal to the solenoid or pilot must be maintained until the table top
has completed its movement.
2) With the locking cylinder of the index ring, the index cylinder retracts,
moving the index arm which in turn rotates the table top.
3) After the index cylinder is fully retracted, the directional control valve
is shifted back. This forces the locking cylinder forward and locks the
table into position. When the locking cylinder locks the table into place,
it pushes the index pawl out of the index ring.
4) With the index pawl clear of the index ring, the index cylinder moves
forward until it hits the stop rod. When the stop rod is adjusted properly,
the index pawl is spring activated into the next slot on the index ring
and the index cycle is complete.
5) The index table is now ready for the next index cycle.
Pneumatics Circuits and Applications
Pneumatic circuit design consideration
When analyzing or designing a pneumatic circuit, the
following four important considerations must be taken into
account:
• Safety of operation
• Performance of desired functions
• Efficiency of operation
• Costs
The typical cost for compressing air to 100 psig (6.8 bar) is
about $0.35 per 1000 ft3 (28.3 m3) of standard air.
Basics Pneumatic circuits
A pneumatic circuit is usually designed to implement the desired
logics. However, there are several basics circuits, which can be
integrated into the final circuit.
Air pilot control of double-acting cylinder
Purpose: To operate a
double-acting cylinder
remotely through the use of
an air pilot-actuated DCV.
How: Using a low pressure
(10 psi) for supplying two
push-button valves and
activating them manually
causes the main DCV to
activate for cylinder
retraction or extension.
Cylinder Cycle Timing System

How: When push-button valve V3 is

momentarily actuated, valve V2
shifts to extend the cylinder. When
the piston rod cam actuates limit
Purpose: To provide a
valve V4, it shifts V2 into its opposite
timed cylinder extend
mode to retract the cylinder. Flow
and retract cycle.
control valve V1 controls the flow-rate
and thus cylinder speed.
Two-step Speed Control System
Purpose: To provide a timed cylinder extend and retract cycle.

How: Assuming that

flow control valve V3
is adjusted to allow
a greater flow-rate
than valve V4.
Initially the cylinder
is fully retracted.

When push-button valve V1 is actuated, air goes through

valves V2 and V3 and the shuttle valve V5 to extend the
cylinder a high speed. When the piston rod cam actuates
valve V6, valve V2 shifts. The flow is therefore diverted to
valve V4 and through the shuttle valve.
The latch(memory) circuit
In this arrangement an output device will remain actuated until
the original fluid power signal is 'cancelled' and a further signal
is provided to actuate the output device in a different mode.

Upon operation of push-button A, a signal is generated at the

2(A) port and the pilot port 14(Z) of valve C. The 5/2-way
memory valve switches and the signal from port 4(A) fully
extends the cylinder F. If the push-button valve A is released, the
signal at 14(Z) is exhausted at the 3(R) port of the push-button
valve A.
The valve C remains in the switched position until the push-button
valve B is operated. If the push-button valve A is released and
therefore there is no signal at 14(Z) then the signal generated by B
will return the memory valve to its initial position and the cylinder
retracts. The cylinder remains retracted until a new signal is
generated at 14(Z) by the valve A. The cylinder piston rod will
extend and retract if there are no obstructions, but there is no
confirmation that the cylinder is in its fully extended position. If
both the 14(Z) signal and the 12(Y) signal are active due to both
push-buttons being operated, then the memory valve will remain in
the last position.
The flow control valves D and E have been fitted to throttle the
exhausting air in both directions of piston motion. The supply air is
transferred through the bypass check valve of the flow control
valves, giving unrestricted supply to the cylinder.
Control of air Motor
Purpose: To control an air
motor
How: When the STRAT
pushbutton valve is
actuated momentarily, the
air pilot valve shifts to
supply air to motor.
When the STOP
push-button valve is
actuated momentarily, the
air pilot valve shifts into its
opposite mode to shut off
the supply of air to the
motor.
 Deceleration Air Cushion of Cylinder
Purpose: To provide an adjustable
deceleration air cushion at both ends
of the stroke of a cylinder when it
drives a load of large weight.
How: Valve V1 supplies air to the
rod end of the cylinder and to the
pilot of valve V5 through flow control
valve V3. Free air exhausting from
the blank end of the cylinder permits
a fast cylinder-retraction stroke until
valve V5 operates due to exhaust is
restricted by valve V7. The resulting
pressure buildup in the blank end of
the cylinder acts as an air cushion to
gradually slow down the large weight
load.
Pneumatic Circuit Design
Implementation of a sequence of actions by a full pneumatic circuit is
widely used in industries. Many industries like automotive, food,
chemical and so on need to use a full pneumatic system due to the
hazardous area in the site and limitation of use of the electricity in the
system.
Example : In a press shop, stamping operation to be performed
using a stamping machine. Before stamping, work piece has to be
clamped under stamping station. Then stamping tool comes and
performs stamping operation. Work piece must be unclamped only
after stamping operation.

Solution Steps

Step 1: Write the statement of the problem:

Let A be the clamping cylinder and B be the stamping cylinder as shown in
the Figure. First cylinder A extends and brings under stamping station
where cylinder B is located. Cylinder B then extends and stamps the job.
Cylinder A can return back only cylinder B has retracted fully.
Step 2: Draw the positional layout.

Cylinder B

Cylinder A
Step3: Represent the control task using notational form
Cylinder A advancing step is designated as A+
Cylinder A retracting step is designated as A-
Cylinder B advancing step is designated as B+
Cylinder B retracting step is designated as B-
Therefore, given sequence for clamping and stamping is A+B+B-A-

Step 4: Draw the

Displacement –step
diagram
Step 5: Draw the Displacement –time diagram
Step 6: Analyze and Draw a Pneumatic circuit.

Step 6.1: Analyze input and output signals.

Input Signals
Cylinder A - Limit switch at home position a0
Limit switch at home position a1
Cylinder B - Limit switch at home position b0
Limit switch at home position b1 Each cylinder has one
change valve (5/2 DCV), and
Output Signal two limit valves (3/2 DCVs)
The forward motion of cylinder A ( A+) (DCV=directional control
valve), and
The return motion of cylinder A (A-) Limit switch = limit valve.
The forward motion of cylinder B ( B+)
The return motion of cylinder B ( B-)
Step 6.2: Using the displacement time/step diagram link input signal
and output signal.
Usually start signal is also required along with a0 signal for obtaining A+
motion.
1. A+ action generates sensor signal a1, which is used for B+ motion
2. B+ action generates sensor signal b1, which is used for B- motion
3. B- action generates sensor signal b0, which is used for A- motion
4. A- action generates sensor signal a0, which is used for A+ motion
The above information (given in 6.2) is shown below graphically

b1
Step 7: Draw the power circuit
i) Draw the cylinders A(1.0) and B(2.0).
ii) Draw the DCVs 1.1 and 2.1 in unactuated conditions
iii) Mark the limit switch positions for cylinders A(1.0) and B(2.0).
Step 8: Draw the control circuit
Step 9: Analysis of pneumatic circuit
1.When the start button is pressed, the signal appears at port 14 of valve
1.1 through limit switch signal a0.
2. Check for the presence of the signal at the other end (12) of valve 1.1.
Notice that the signal is also present at port 12 of valve 1.1. (because b0 is
also pressed). This results in signal conflict and valve 1.1 is unable to
move.

3. Let us assume for time being, b0 is somehow disengaged so that valve

1.1 can switch over and consequently cylinder A can extend. When the
start button is pressed.
4. When cylinder A fully extends, it generates a limit switch signal a1,
which is applied to port 14 of the valve 2.1.
5. Check for the presence of the signal at the other end (12) of valve 2.1.
Signal is not present at port 12 of valve 2.1 and hence there is no signal
conflict
6. Signal applied to port 14 of the valve 2.1 causes the shifting of DCV
2.1 and cylinder B extends.
7. When cylinder B fully extends, it generates a limit switch signal b1,
which is applied to port 12 of valve 2.1
8. Check for the presence of the signal at the other end of 14 of valve
2.1. It can be seen that signal is also present at the port 14 of valve
2.1(because a1 is also pressed).
This results in signal conflict and valve 2.1 is unable to move
9. Let us assume for time being, b1 is somehow disengaged so that valve
2.1 can switch over and consequently cylinder B can retract.
10. When the cylinder B is fully retracted, it generates a limit switch signal
b0, which is applied to port 12 of the valve 1.1.
11. Check for the Solution
signal at the other
end 14 of the
valve 1.1 Notice
that signal is not
present at port 14
of the valve 1.1
and hence there is
no signal conflict.
So valve 1.1 can
switch over and
Cylinder A can
retract.
Another solution ( Advance)
Using PLC Sequential Programming

Introduction
Most machine operations are sequential in nature so it is necessary for the
PLC to switch outputs depending not only on the input combinations but also
on the current stage in the sequence. An output operating at the wrong time
could cause damage or injury so the correct programming technique is critical.
The two cylinders A and B in Fig are to go through the sequence A+ B+
A- B- . Reed switches a-, a+, b- and b+ have been fitted to detect the
magnetized cylinder pistons through the aluminum cylinder bodies. The
5 port 2 position directional control valves (5/2 DCVs) are
double-solenoid operated.

Each event in a sequence is started by the completion of the previous

event. When reed switch a+ ,for example, closes, it signals the end of
event A+ (the extension of cylinder A) and the beginning of B+ (the
extension of cylinder B). We will write the program line-by-line on this
basis.
Input

PLC

Output
 Let’s try for example, this sequence using the hardware.

A+ B+ A-B-
The PLC wiring diagram is shown in Fig

Pressing the Start button causes the cycle to execute once. The reed
switch b- is not required neither is the Stop button
Latching on the Start button with an internal relay and incorporating the
reed switch b- causes the cycle to repeat until the Stop button is pressed.
It all seems pretty straightforward so far doesn’t it? Let’s try another
sequence using the same hardware.

A+ B+ B- A-
I have entered the ladder logic in a similar way to the first sequence.
Everything works fine until we get to the third rung of the program where
the reed switch b+ is supposed to energize solenoid Y4 to cause cylinder
B to return. At this point both cylinders are extended.
The fact that cylinder A is also extended means that reed switch a+ is
closed and therefore solenoid Y3 is energized, cylinder B therefore
cannot return. This situation is called a trapped signal. It is
characterized by having both solenoids of a double solenoid directional
control valve simultaneously energized and it prevents us from
programming many circuits in a simple sequential fashion.

The realization of this sequence is even more difficult using

single-solenoid, spring return directional control valves because
latching is required and we are still only dealing with a two cylinder
problem.
Trapped signals also occur in pneumatics and in electro-pneumatics and
various methods are employed to get over the problem. The best known
of these is the cascade system but it is only of practical use in simple
systems.
They can be further classified into two categories
a) Memory box with set priority
b) Memory box with reset priority
The functions of a memory box are similar to the memory coils. In the
memory box with set priority, the associated memory address is set when
signal state 1 appears simultaneously at both the set and reset inputs. In
the memory box with reset priority, the associated memory address is reset
when signal state 1 appears simultaneously at both reset and set inputs.
Example 1: Double-acting cylinder is used to perform the pressing operation. The
cylinder has to move forward when PB1 button is pressed and return for a set time
of 20 seconds before it automatically returns to its initial position. Limit switch S2
is used for end sensing of the forward motion of the cylinder. Draw the pneumatic
circuit, PLC wiring diagram, and ladder diagram to implement this task.
Example 2:
Double-acting cylinder
is used to perform
continuous to and
from motion. The
cylinder has to move
forward when PB1
button is pressed and
once to and from
reciprocation starts it
should continue till the
stop button PB2 is
pressed. Limit switches
are used for
end-position sensing.
Draw the pneumatic
circuit, PLC wiring
diagram, and ladder
diagram to implement
this task.
Example 3:
Double-acting
cylinder is used to
perform to and fro
operation. The
cylinder has to
move forward when
PB1 button is
pressed and
continue to and fro
motion till 10 cycles
of operations are
performed. Draw
14=1, O2=1, Y is ON
the pneumatic
circuit, PLC wiring
diagram, and ladder
diagram to
12
implement this task.