Ch.

1-
Pneumatics

EET 337
Pneumatics and Hydraulics System
 Contents
1) Introduction to fluid power
2) Applications of pneumatics
3) Pressure measurement units
4) Pneumatic system structure and signal flow
5) Symbol and drawing circuit diagrams
6) Components of pneumatic systems
 Air generation and distribution components
 Actuating devices
 Signal input, processing and signal output valves

7) Introduction to FluidSIM 3.6 Pneumatics simulation

software
8) Development of pneumatic control systems
2 9) Advanced pneumatic components
 Objectives

By the end of the chapter, you will able to:

 Explain the signal flow and structure of pneumatic
system
 Read, describe and draw the symbol and drawing or
circuit of pneumatic systems
 Describe the operations of pneumatic components
 Draw and simulate pneumatic circuits using FluidSIM
 Develop pneumatic system
 Describe operation of advanced pneumatic

3 components
 1. Fluid power

 Source of energy for industrial processes

– Electric energy- electric motor
– Fluid power – cylinder (piston)
 Fluid power- deals with ways of using pressurized
gas (usually air) or liquid (usually oil) for doing work.
 The two forms named as
– Pneumatic – pressurized air
– Hydraulic – pressurized oil

4
 Pneumatic system

 Initially it is used for carrying out the simplest

mechanical tasks (pneumatics)
 Now has played a vital and important role in automation
and development of sophisticated technologies with
electronic control such as PLC, solenoid valves
(electropneumatics) and continuous valves.
 In this chapter we will learn and practice controlling
pistons using mechanically and pneumatically
controlled valves.

5
 2. Application of pneumatics

 The applications for compressed air are limitless - from

low to high pressure
– The optician’s gentle use of low pressure air to test
fluid pressure in the human eyeball (0.23-0.43 psi),
– The multiplicity of linear and rotary machines in
robotic process machines
– The high forces required for pneumatic presses and
concrete braking and pneumatic drills.

6
 Some of the pneumatic
applications in our life:

 In
automotive
service

7
 Some of the pneumatic
applications in our life:

 In medical service  In construction sector

8
 Pneumatic industrial applications
 Operation of system valves for air (gas), water, chemicals
 Operation of heavy or hot doors
 Unloading hoppers in building, steel making, mining and
chemical industries (funnel-shaped dispenser or vehicle that
discharges load through floor)
 Ramming and tapping in concrete and asphalt laying
(battering or crushing devices – common is hydraulics ram)
 Lifting and moving in slab molding machines
 Bottling and filling machines
 Component or material transfer conveyer
 Pneumatic robot
9
 Pneumatic industrial applications
 Air separation and vacuum lifting of thin sheets
 Holding and moving in wood working and furniture making-
Wood working machinery drives and feeds
 Holding in jigs and fixture in assembly machinery and machine
tools- Machine tool, work or tool feeding
 Holding for gluing, heat sealing or welding plastics- Holding for
brazing and welding- Spot welding machines
 Forming operations of bending, drawing and flattening
 Operation for guillotine blades (instrument for cutting metal or
paper)
 Test rigs

10
 3. Pressure measurement units

Quantity Symbol SI unit Name Remarks

Pressure p Pa Pascale 1Pa=1N.m-2
Standard Vn m3n Standard At T=00C and
volume cubic meter P=760mmHg=14.696
psi
Volume flow Q m3n . s- Standard
1 cubic
meter/sec
Temperature T 0K Kelvin 0 0C =273.16 0K
Energy, work E, W J Joule 1J=1N.m=1Pa.m3
Power P W Watt W=N.m.s-1 , P = p.Q

11
 Conversion table for the two
measurement systems

12
 Practical values
 It should be noted that the SI unit of pressure is Pascal (Pa).
However, this unit is very small and so to avoid huge
numbers in practice, an agreement has been made to define
and use another large unit called bar. It is defined as
1bar = 100,000 Pa (100KPa)
 Its Imperial equivalents are
1 STD atm = 14.696 psi = 1.01325 bar
 A pressure in the context of pneumatics is assumed as
over-pressure i.e. above atmospheric pressure
– i.e. above 14.7 psi or 1 bar up to 10 bar or 145 psi
(commonly referred to as gauge pressure (psig)).
13
 4. Pneumatic system structure and
signal flow

 A simple pneumatic system

 It consists of an interconnection of three elements.

14
  Depiction of
the general
structure
and signal
flow of
pneumatic
system

15
  An example
of
pneumatic
circuit

16
 5. Symbols and circuit diagrams
standards

 The main standards for symbols and drawing the circuit

drawings of fluid power system are follows.
– Symbols must be created to standards BS-2917/ISO-
1219 -1.
– The layout of the drawing should conform to ISO
1219 – 2
– The standards for connections to the hardware are
covered by ISO 9461.
– Each component on the circuit diagram should be
numbered and annotated with essential data such
as pressure settings and capacity.
17
 Numbering system
 The number should consist of four parts. Consider the
identification tag 2 – 3V5
 The first number is the installation number. If there is only
one, it may be omitted.
 The second number is the circuit number and again if there
is only one, it may be omitted. Number 0 is used for the
drawing of the power pack and accessories.
 The letter identifies the type of the components as follows:
– P: Pump, A: Actuator, M: Prime Mover, S: Sensor, V:
Valve, Z: or any other appropriate letter is used for any
other component
 The last number is the sequence number of the component
18 so V5 means valve number 5.
 Example

 A standard
drawing has
– Circuit
diagram
– Component
list
– Title block
 An example of 2-1Z3
circuit
diagram is
shown
19
 6. Components of pneumatic
system

 Pneumatic components can be classified into three

general groups:
– Air generation and distribution components
(compressor-air cooling (drying)-reservoir-air
service units and other accessories)
– Actuators (pistons, air motors, rippers etc.)
– Valves (Input valves, processing valves and control
valves as we have seen in the structure of
pneumatic system)

20
 i) Air generation and distribution
components

 Main function is to provide the system with

compressed air which is dry, clean, and at the
required pressure.
 Air is compressed by the air compressor and
delivered to an air distribution system in the
factory.
 To ensure that the quality of the air is acceptable, air
service unit is utilized to prepare the air before being
supplied to the control system.
 Malfunctions can be considerably reduced in the
system if the compressed air is correctly prepared.
21
 Air compressor

 Used to produce the compressed air for the system

by the required volume and pressure.
 As a rule, pneumatic components are designed for a
maximum operating pressure of 800-1000 kPa (8 - 10
bar) but in practice it is recommended to operate at
between 500-600 kPa (5 and 6 bar) for economic and
safe use.
 Due to the pressure losses in the distribution system,
the compressor should be delivered between 650-700
kPa (6.5 -7 bar) to attain these figures.

22
 Air compressor symbol

 Figures below is an example of air compressor and its

ISO symbol.

23
 Types of compressors

 The principal types of compressors

24
 Single stage reciprocating piston
compressor

 Downward
movement causes
air to enter the
cylinder through the
inlet valve
 Upward movement
closes the inlet valve
as the air is
compressed forcing
the outlet valve to
open and discharge
the air to the tanker

25
 Air drying unit
 As the air from the compressor is very hot and humid, the cooling
and drying unit is used to reduce the compressed air temperature
and condensate the water vapor (humidity) and remove from the
compressed air.
 The accumulation of condensate depends largely on the relative air
humidity of the intake air that depend on the surrounding air
temperature and the weather situation.
 The most effective way to remove the major part this condensate is
to use an aftercooler immediately after air compression.
 Aftercoolers are heat exchangers, being either-air cooled or
water-cooled and have an auto-drain to remove the accumulated
condensation.
 To remove the humidity, we may also use other many types of air
dryers.
26
 Air dryers
 In addition to aftercooler there are other
types of dryers that can condensate the
water vapor from the compressed air that
pass through them. They are
 Absorption dryers- Dehydrated chalk or
magnesium chloride or calcium chloride
reacts with the moisture to form a solution
which drained from the bottom of the
vessel- (see Fig)
 Adsorption dryers- silica gel or activated
alumina to physically absorb moisture from
the compressed air and retain it inside then
drained the water by pressurized gas.
 Refrigerator – It is a separate refrigerating
unit which not an integrated part with the
27 compressor.
 Air dryer symbol

 Figures below show some example of real aftercooler and air

dryer and an ISO symbol of air dryer.

28
 Air Tank (reservoir)

 An air reservoir should be fitted

– To store and stabilizes the compressed air,
– To minimize the frequent run and stop of the
compressor or motor and
– To provide an additional cooling of the air.
 It is fitted with a pressure gauge, safety valve,
automatic drain, and inspection for checking and
cleaning inside.

29
 Air Tank symbol

 Figure below shows a real air tank and ISO symbol of

an air reservoir.

30
 Piping and its layout

 Two types of layout - Ring and Dead-end lay out

 Ring type is shown in figure below is the most frequent for better
supply flow
 Fed air from two
sides to a point of
high consumption
& reduce pressure
drop
 But drive
condensate in any
direction requiring
sufficient water take
off point
 And additional return
31 pipe cost
 Dead-end layout
 The pipe lines must be installed in the direction of flow with a gradient
of 1 to 2% thus condensate can be removed from the lines at the
lowest point.
 Branching
– Air-
takeoff –
upper
side of
main pipe
– Drain -
underside
of main
pipe

32
 Typical ring layout

33
 Typical dead-end layout

34
 Main piping materials

 The are different materials for the main piping in different

standard size.
– Standard Gas Pipe (SGP) – steel or malleable pipe
obtained either in black or galvanized
– Stain less steel pipe- when large diameter in long
straight main are required
– Copper tube – where corrosion, heat resistance and
high rigidity are required but costly for more than
28mm diameter pipe
– Rubber tube (Air Hose/ reinforced plastic )- they are
most suitable for air actuated hand tools as it offers
35 flexibility for freedom of movement for operator
 Plastic tubing and fittings

 Figures below show some types of tubes that are

commonly used in connecting pneumatic components
and associated fittings such as T connections and
cross connections.

36
 Fittings

 A push-in  A self-sealing
fittings elbow fitting elbow
type type
37
 Shut-off valve

 It is used to open and close the compressed air supply

manually.
 Figures below show a sample of shut-off valve and the
ISO symbol of the shut-off valve.

38
 Pressure gauge

 It used to display the actual amount of the pressure

mostly in two main units Pascal and bar (1 bar = 14.5 psi
(pressure per square inch)).
 Figures below show a real pressure gauge and the ISO
symbol of the pressure gauge.

39
 Air service units

 The air service unit is a combination of the following:

– Compressed air filter (with water separator),
– Compressed air regulator and
– Compressed air lubricator.
 The main function of the service unit is providing the
pneumatic system with a well cleaned, lubricated and
regulated compressed air.

40
 Air service units symbol

 Figures below show a real service unit (filter and

regulator), its ISO symbol and also the simplified symbol.

41
 Air filter
 Compressed air filter has the job of
removing all contaminants from the
compressed air flowing through it as well
as water which has already condensed.
 The compressed air enters the filter bowl
through guide slots. Liquid particles and
larger particles of dirt are separated
centrifugally collecting in the lower part of
the filter bowl. The collected condensate
must be drained before the level exceeds
the maximum condensate mark, as it will
otherwise be re-entrained in the air
stream.
 Two types of drain – manual and auto
42 drain
 Air filter symbols

 Figures below shows air filter and the ISO symbol of an

air filter.
Filter general symbol

Filter with water trap

(manual drain)

Filter with water trap (auto-

drain)
43
 Pressure regulator

 Its purpose is to keep the operating pressure of the

system (secondary pressure) virtually constant
regardless of fluctuations in the line pressure (primary
pressure) and the air consumption.
 Figures below show a regulator and the ISO symbol of
the air regulator.

44
 Air lubricator

 Most moving parts require some type of lubrication.

 The efficiency of cylinders, valves and air motors can
be greatly improved if they are supplied with adequate
lubrication.
 Pneumatic components can be lubricated by using an
airline lubricator - a device for adding lubricating oil in
aerosol form into a compressed air line.
 The air passing through the lubricator transports the
lubricant to air tools, cylinders or other air operated
equipment.

45
 Air lubricator symbol

 Figures below lubricator and its ISO symbol of the air

lubricator.

46
 Manifold

 It is used to provide multi equal pressure outlets. Each

output port has check valve (Non return valve).
 Figures below show a pneumatic manifold (distributor)
and its ISO symbol of the pneumatic manifold.

47
 ii) Actuators

 Pneumatic actuators will convert compressed air energy

into mechanical energy. They can be:
– Piston cylinders – linear movement
– Rotary actuators- reciprocating rotary motion with
an angle 2700 by vane or rack and pinion type
actuators and continuous rotation by air motor.
– Different types of air tools and grippers.
 Linear cylinders of varying design are the most
common power components used in pneumatic
automation.
 There are two basic types of piston cylinders: single
48 acting and double acting cylinders.
 Single acting cylinder

 Powered only in one direction and needs another force to

return it such as an external load (as in car jack) or a
spring.
 Used for clamping, marking, ejecting etc.
 They have somewhat lower air consumption compared
with the equivalent size of double acting cylinder.
 However there is a reduction in trust due to the opposing
spring force, and so a larger bore may be required.
 Also accommodating the boring results in a longer
overall length and limited stroke length.

49
 Single acting symbol

 Diagram and symbol

Spring

50
 Double acting cylinder

 A cylinder in which air pressure may be alternately

applied to the opposite side of the piston to drive it in
extending or retracting direction.
 The trust available on the retracting stroke is reduced
due to the smaller effective piston area, but only
consideration if the cylinder to pull the same load in both
directions.
 Cylinders capacity expressed in terms of - operating
pressure ranges, strokes length, piston-rod diameters,
thrust values at a certain pressure, speeds, approachable
positions
51
 Double acting symbol

 Diagram and symbol

52
 iii) Valves
 Valves are used to control the direction of flow of the
fluid.
– Input valves - manual operated and mechanical
operated (limit switch) valves
– Output valves – valves that control the air supplied to
the actuating device- pneumatically operated valve
– Processing valves – used to implement the control
algorithm of the system – they control the output
valves based on the information they received from
the input valves.

53
 Directional valves

 They are specified in terms of the number of ports and

number of controlled positions they have.
 Figure below shows the symbol of a 4/2 way valve.
 It means the valve has 4 ports or connections designated
with letters A, B, P, and T(S) and 2 switching positions
designated with two adjacent boxes, with the left
connected to push button and the right with spring.

54
 Valves

 Mushroom valves

55
 Valves

 Flat slide valves

56
 Valves

 Plate slide valves

57
 Valves

 Plate slide valves

58
 One way flow control valve

 Operation

59
 Quick exhaust valve

 Functions in a similar way as the check valve. The air

flow from P to A is free, the rubber gasket lies on right,
and its gasket component is bent inwards. When
pressure falls at P, the air flow coming from A sets the
valve on the left side and opens the path to the outlet
through the exhaust silencer.

60