EENG 110 APPLICATIONS WITH PNEUMATICS

 Chemical Industry
LECTURE 1:  Petrochemical Industry
 Food Industry
Festo  Packaging industry
- German multinational company  Printing and Paper Industry
- Founded in 1925  Drinking Water and Waste Water
- By Albert Fezer and Gottlieb Stoll
Pneumatics STRUCTURE AND SIGNAL FLOW OF
- From Greek word “pneuma” which means PNEUMATIC SYSTEM
“to breath”
- Branch of fluid power
- Uses compressed air or other gasses
Electricity – medium used is electric current
Hydraulics – medium used is liquid
Mechanics – medium used is mechanical motion

APPLICATIONS OF PENUMATICS
TECHNOLOGY
 Bus Doors
ENERGY SUPPLY
 Automatic Production Lines
 Bottle Filling System
 Conveyors
 Pick and Place System

ADVANTAGES OF COMPRESSED AIR

 Availability – air is available everywhere
 Transport – air is easily transported in
pipelines
 Storage – compressor does not need to
be in continuous operation
o Compressed air can be stored in
reservoir
o Reservoir is transportable
Compressor
 Temperature – compressed air is
- Mechanical flowing device designed to
insensitive to temperature fluctuations
increase pressure of gas by reducing
 Overload Safe – pneumatic tools can be
volume
loaded to the point of stopping
- Main component of basic refrigeration
 Cleanliness – unlubricated exhaust air is
- Heart of a cooling system
clean and does not cause contamination
- Works as pump
 Components – components are simple to - Energy source of pneumatic systems
construct - Provides operating pressure
 Speed – compressed air is very fast - Most Common are reciprocating and
o High working speeds are screw compressors
obtainable - Atmosphere: p = 0 bar
- Compressor: p = 5-7 bar
DISADVANTAGES OF COMPRESSED AIR - Multi-stage reciprocating compressor
 Preparation – dirt and condensate should o Attain higher operating pressure
not be present o Provide cooling of compressed air
 Compressible or Non-Uniform Force –
constant piston speed is hard to achieve
 Force Requirement – small loads of
<50kN -
 Noise Level – exhaust is loud but is solved Fluid
- Substance with no fixed shape
by silencers
 - Yields easily to pressure Actuators
- Gas or liquid - Output device convert supply energy to
Air Receiver useful work
- store compressed air before it enters - Linear Motion:
Air Service Unit Parts o Produce motion in straight line
- Air Filter o Pneumatic and hydraulic cylinders
- Pressure Regulator mostly used to produce linear force
- Air Lubricator o Single acting cylinders
- Pressure Gauge  One-direction, uses spring
 Forward Effective Force
 F= p∗a−F FR−F S
 Return Effective Force
 F=F S−F FR
o Double acting cylinders
- Rotary Motion
o Air Motor
o Rotary Actuators
- End Effectors
Filter - Linear Actuators
- Cleans compressed air by removing o Produce motion in straight line
impurities: o Pneumatic and hydraulic cylinders
o Dust mostly used to produce linear force
o Small particles Rotary Actuators
o Pipe scales - Rotational motion in a limited angle
o Rust - Swivel is made by rotary and vane
o Water condensate cylinders
o Oil - Rotary Cylinders
o Without water drain o Double acting cylinder with internal
teeth
o Uses teeth and gear wheel to turn
linear to rotary

o With water drain

o
 Applies to all vane and
Centrifugal Separator
rotary cylinders
- Filter for water droplets and large dusts
- Rotary Vane Cylinders
(>50 microns)
o Energy is directly converted to
Pressure Regulator
rotary motion
- Used to obtain:
o Does not use teeth and gear
o Uniform speed
o Force directly transmitted to the
o Uniform force and torque
shaft
- Rotary Vane Motors
Pneumatic Motors
- Transform pneumatic energy to
- continuous rotary motion
Lubricator
- Gives compressed air with fine oil mist
(lubricant)
- Should be used sparingly to avoid
clogging
 LECTURE 2:

Energy supply is always drawn at the bottom of

the diagram
Control System
- Device that controls the cylinder
Directional Control Valves
- Devices which influence the path of air
- Used to control drive components
SYMBOLS:
 Valve switching position
 Number of squares = number of switching
positions
 Lines indicate flow path
 Arrows show direction of flow
 Shut-off positions are lines drawn at right
angles (T or perpendicular)
 Connections (both inlet or outlet) are lines
outside the box

METHODS OF ACTUATION
Manual Operated – simple levers and paddles
 Lever
 Pedal
 General
 Detent
 Push button
Mechanical
 Roller
 Ball Seat
DESIGNATION OF WORKING AND PILOT
 Idle roller
LINES ON DIRECTIONAL CONTROL VALVES
Pneumatic – switching by air signal to pilot part
Connection Function Designation
 Air Pilot/Spring Return
Working Supply 1
Lines (all Working 2,4  Air Pilot on both sides
valve types) Exhaust 3,5 Combined – DCV contains more than one
Pilot Lines Close Supply Port 10 operation
1-2 Connection 12
1-4 Connection 14 VALVES
Auxiliary Pilot Air 81,91  2/2-way valves
 3/2-way valve ball seat
METHODS OF ACTUATION  3/2-way valve
 Manual Operated  3/2-way valve disc seat
 Pneumatic Operated  3/2-way valve roller operated
 Electrical Operated  3/2-way valve single pilot
 Combined Operated  4/3-way valve mid position
 5/2-way longitudinal slide valve
 5/2-way valve double pilot
 5/2-way valve
 5/3-way valve
 LECTURE 3 - Directly on cylinder or as near as possible
WAYS OF THROTTLING USING ONE-WAY
Noise Attenuation on Exhaust FLOW CONTROL VALVE
- Resolved by silencers and mufflers at Exhaust Air Throttling/Metering Out
exhaust ports - Supply air freely to piston side and one-
Silencers/Mufflers way flow control valve is connected to
- Also reduces speed of exhaust exhaust side to offer resistance on
- Increases area over which flow takes discharge side
place - Advantage of exhaust-air flow control is
Shuttle Valves chamber is filled quickly to build minimum
- Logical-OR operation pressure to generate motion
- Continuous motion free from stick/slip
effect
- Supply Air Throttling/Metering In
Dual Pressure Valves - No air cushioning at exhaust, and one-way
- Logical-AND operation flow control valve is connected to supply
to restrict incoming flow
- Used for cylinders with small diameter or
- short stroke
Non-Return Valve or Check Valves - Operate with small amount of air
- Allow fluid to pass only in one direction - Effect of air cushion would be too small
- Bypass device - Used with single-acting cylinders if speed
- is limited in stroke direction where relevant
cylinder chamber is filled with air
- Mostly used with single-acting cylinders

-
APPLICATION OF CHECK VALVES
 Bypassing flow to a device in specific
direction
 Protection of pump to back-pressure
 Vacuum system
Flow Control Valves
- Restricts flow of air to reduce flow rate
- Reduce pressure build to reduce speed

-
- Influence volumetric flow rate
- Generally adjustable and can be locked
- Never close flow control valve completely
One-Way Flow Control Valve
- Combination of flow control valve and non-
return valve
- Free flow in one direction
 LECTURE 4
Electropneumatics
- Integration of electrical and electronics
technology to pneumatics technology
- Includes electrical switches, relay,
contactors, etc.
Electrical and Electronics Technology
- Used as the control device
- Flexibility, ease of installation, and
compactness
Pneumatics Technology
- Used as power device
PNEUMATICS
1. Signal Input – input elements
 Directional control valves
i. Mechanically operated
ii. Manually operated
 Air barriers
2. Signal Processing – processing elements
 Directional control valves
 Shuttle valves
 Two-pressure valves
 Pressure control valves
 Sequencers
3. Signal Output – final control elements
 Directional control valves
4. Command Execution – power component
 Cylinder
 Swivel cylinder
 Pneumatic motors
 Optical displays
ELECTROPNEUMATICS
1. Signal Input – input elements
 Pushbuttons
 Control switches
 Limit switches
 Reed switches ADVANTAGE OF ELECTRICAL/ELECTRONIC
 Inductive proximity sensors CONTROL
 Capacitive proximity sensors 1. Increase reliability
 Light barriers - Less wear
 Pressure-actuated switches - Mechanically moving parts
2. Signal Processing – processing elements 2. Reduced commissioning complexity,
 Relays particularly in complex control systems
3. Reduced installation expenditure
 Contactors
4. Simple exchange of information or signals
 Programmable logic controllers
DIRECTIONAL CONTROL VALVES
(PLCs)
1. 2/2 Way Valve
3. Signal Output – final control elements
 Electropneumatically operated
directional control valves
4. Command Execution – power components
 Cylinder
 Swivel cylinder
 Pneumatic motors
 Optical displays
 2. 3/2 Way Valve - Generates a magnetic field around it when
an electric current is passed through the
conductive wire
OTHER ELECTRICAL COMPONENTS
Power Supply Unit
- Signal control section of an electro-
3. 5/2 Way Valve pneumatic controller
- Supplied with power via the electrical
mains
- The power supply converts the incoming
230VAC to 2VDC

4. 5/3 Way Valve

CONTROL ELEMENTS
Solenoid Valves
- solenoid + valve Electrical Switches
- uses solenoid to actuate the valve - Installed in a circuit to open or close the
- valves actuated electrically flow of current to the consuming device
Electropneumatic Valves - Breaks or closes circuit connections used
- pneumatic valves actuated electrically to turn on/off system, a device (load) or a
- examples: station
o 2/2-Way Valve, Solenoid Actuated, - Two common types
o Momentarily activated
Spring Returned

o Mechanically interlocked
o 3/2-Way Valve, Solenoid Actuated,
(detented)
Spring Returned

 Also called rocker switch

o 3/2-Way Valve, Double Solenoid
o 5/2-Way Valve, Solenoid Actuated,
Spring Returned
o 5/2-Way Valve, Double Solenoid
o 5/2-Way Valve, Double Solenoid,
Spring Centered
Solenoid
- Electromagnetic device used to generate
magnetic field causing mechanical pull or
push
o Linear motion usually
- Long thin loop of conductive wire wrapped
around a magnetic core
 Mechanical latching
- Configuration of Switches
o Normally open (make switch)
 Path 3 to 4
o Normally close (break switch)
 Path 1 to 2
o Changeover contacts
 Path 1 to 2
 Path 1 to 4
Multiple-Pole & Detent Switch
- Switch with multiple set of contacts (pole)
and one actuating element
Relays DIRECT AND INDIRECT CONTROL CIRCUIT
- Serves as foundation for building hard- Pneumatic Circuit
wiring electrical control of automated
systems
- Electromagnetically-actuated switch that
switches contact via electrical current that
produces magnetic field

Direct Control Indirect Control

Electrical Circuit

ADVANTAGES OF RELAYS Direct Control Indirect Control

1. Easily adapted to various operating
voltages
2. Not much affected by ambient Indirect Control – usually means having a relay
temperature
3. Ideally infinite resistance between
contacts in the off-state
4. Ideally zero resistance between contacts
in on-state
5. Several independent circuits can be
switched
DISADVANTAGES OF RELAYS
1. Working surface of contacts wear through
oxidation
2. Larger space requirements compared to
transistors and thyristors
3. Noise is created during switching
operation
 Due to current generated magnetic
field which in turn induces current
to other circuits
4. Limited switching speed
 3 ms to 17 ms
5. Relatively low pick-up time compared to
transistors and thyristors

APPLICATION
1. To multiply signals
2. To link information/signals
3. To separate the control and main circuits
 LECTURE 5
Timers and Time Relays OFF DELAY TIMER
- Used when timing applications is needed
o Delaying the start of a machine
o Delaying the turning off of the
machine
o Example
 Oven
 Machine tower lights
 Stop lights
 Urinals
- 2 types of time relay
o Pull-In Delay (ON Delay)

ON DELAY TIMER

Counters
- Used when counting applications is
needed
- Ex.
o Counting bottles passing through
 the conveyor belt
o Drop-Out Delay (OFF Delay) o Counting the number of cars
entering and leaving the parking
area
o Counting the number of
workpieces transferred


 LECTURE 6
Sensors Through Beam Sensors
- Devices which measure/detect/sense
physical parameters and converts it to a
signal
- Classification of Sensors
o Contact Types
 Limit switches
 Force sensors
 Pressure sensors
 Temperature sensors
 PH sensors
o Non-Contact Type (Proximity
Sensor)
 Proximity sensors
 Light barrier
 Ultrasonic
Retro-Reflective Sensors
 Magnetic
- Categories of Sensors
o Binary/Discrete
 Convert physical quantity
into a binary signal
 Two switching states
 Electrical signal ON or OFF
o Analogue/Analog

OPTICAL OR PHOTO ELECTRIC SENSORS

Optical Sensors
- Installed in different configurations with
regards to the transmitter and receiver
locations and orientations

Capacitive Sensors
- Highly used in proximity detection of
insulative materials as well as conductive
materials
- Detection depends on the di-electric
constant of material
ADVANTAGES OF CAPACITIVE SENSORS
1. Detect various material types either
insulative or conductive materials
2. Detect objects inside another object
because of dielectric constant values
 3. Detect even the darkest color which
optical sensors cannot do
4. Ability to distinguish material according to
type using dielectric constant
LIMITATIONS AND DISADVANTAGES
1. Very short distance coverage
2. Transmitter and receiver is a single unit
which cannot be configured in different
installations
3. Highly affected to EMI (electromagnetic
interference)
4. Inability to distinguish material according
to color
USAGE OF CAPACITIVE SENSOR
1. Sensor is adjusted so that it does not see
the wall of the vessel
Dielectric Constant

2. As the level rises the fluid affects the

sensor field

IEC 60617

3. Until the sensor switches

EN 81346-2

Inductive Sensors
- Used in proximity detection of a wide
range of metals
- Bigger coil, greater active switching gap
- Can only detect metals
- Different switching distances for different
metals

IEC 60617
- Contains graphical symbols for use in
electrotechnical diagrams
EN 81346-2
- For letter designations for use industrial
systems and installations