SAFETY

RECOMMENDATIONS
• Do all the connections and disconnections
with the energy supply OFF!
• Things to do in case of loose tubes
whiplash:
– Put the system into zero pressure status
– Hold the tubes (if you can) then turn off the
energy supply
– Back off and have the attention of the
operator to turn off the energy supply
 SAFETY
RECOMMENDATIONS
• Check all the components/devices for
proper connections and orientations
before turning the energy supply ON.
• Avoid using tubes with defects
• Refer to the instrument’s user manual for
its care and safe use
• Maintain the standard compressed air
pressure : 5 bars
 Do’s inside the
Mechatronics Laboratory
• Keep your working area clean and
organized.
• Do your work quietly
• Arrange the chairs before you leave.
• Read and follow the safety precautions
given here to avoid any untoward incidents.
• Follow the proper procedure in
disconnecting tubes/hoses.
• Take care in performing any laboratory
experiment and handling materials
 Don’ts inside the
Mechatronics Laboratory
• Do not eat, drink or smoke inside the
laboratory.
• Do not play with the experiment and
experiment materials while performing the
experiment.
• Do not perform an experiment with your
hands wet.
• Do not panic in case of an air whiplash.
 Pneumatics
Pneumatics

-study of air movement and air

phenomena
-from the Greek word “pneuma” which
means breath or wind.
-branch of engineering science that
pertains to gaseous pressure and flow

-the portion of the fluid power in which

compressed air or other gas is used to
transmit and control power to actuating
mechanisms.
 Advantages of compressed air:

• Availability- air is available practically everywhere

in unlimited quantities.
• Transport- air can be easily transported in
pipelines/ tubes.
• Storage- compressed air can be stored in a
reservoir and removed as required.
• Temperature- compressed air is relatively
insensitive to temperature fluctuations. This
ensures reliable operation, even under extreme
conditions.
• Explosion proof- compressed air offers no risk of
explosion or fire.
• Cleanliness- unlubricated exhaust air is clean.
• Speed- compressed air is a very fast working medium.
• Overload safe- pneumatic tools and operating
components can be loaded to the point of stopping
and are therefore overload safe
 Disadvantages of
Pneumatics
• Preparation- compressed air requires good
preparation. Dirt should not be present.
• Compression- it is not always possible to achieve
uniform and constant piston speeds with
compressed air.
• Force requirement- compressed air is economical
only up to a certain force requirement. Usually up
to 30kN.
• Noise Level- the exhaust air is loud. This problem
has now, however been largely solved due to the
development of sound absorption material and
silencers.
 General methods of
material handling
– clamping
– shifting
– positioning
– branching of material flow
 General Applications:
– Packaging
– Filling
– Metering
– Locking
– Driving of axes
– Door or chute control
– Transfer of materials
– Turning and inverting of parts
– Sorting of parts
– Stacking of components
– Stamping and embossing of components
Control Chain/ Component Placement
Energy Supply
 Air Service Unit
• It is used to ensure the quality of
the air being applied to the control
system is acceptable.
• Composed of 3 elements:
– Compressed Air Filter
– Compressed Air Regulator
– Compressed Air Lubricator (optional)
Air Service Unit
 Air Cylinder
• An operative device in which the
static input energy of compressed air
is converted into mechanical output
power by reducing the pressure of
the air to that of the atmosphere.
Two Types of Cylinders

• Single Acting Cylinder

• Double Acting Cylinder
 General characteristics
of pneumatic cylinders

• Diameters: 2.5 to 320 mm

• Stroke lengths: 1 to 2000 mm
• Available forces: 2 to 45000 N at 6
bar
• Piston speed: 0.1 to 1.5 m/s
 Single Acting Cylinder
• A single acting cylinder is only capable
of performing an operation motion in
one direction.
 Double Acting Cylinder
• Double Acting Cylinders are capable of
performing an operation motion both
direction of the piston travel.
 Pneumatic components can
perform the following types of
motion:
• Linear
• Rotary
• swivel
Output Devices
Single Acting Cylinder vs
Double Acting Cylinder
 Air Motor
• Pneumatic Motors are represented
by means of a circle which shows
where the drive or output shaft is
located. Triangles within the circle
give information about the direction
of flow.
 Valves

• Valves are devices to control or

regulate the commencement,
termination and direction and also
the pressure or rate of the flow of a
fluid under pressure which is
delivered by a compressor or vacuum
pump.
Four Principal Groups of Valves
Accrdg. To Their Function

• Directional Control Valves

• Non-Return Valves
• Pressure Control Valves
• Flow Control Valves
I. Directional Control Valves
• Controls the passage of air signals
from the input side of the element to
the output side by generating,
canceling/relieving or redirecting
signals.
• Characterized by its method of
actuation and # of controlled
connections or ways and switching
positions.
Directional Control
Valves
Directional Control Valves
Port Designations
 II. Non – Return Valves

• It permits the full flow in one

direction and fully blocks the flow in
the other direction.
Types of Non – Return
Valves
• Non Return Valve
• Shuttle Valve
• Dual Pressure Valve
• Quick Exhaust Valve
• One – way Restrictor
 Non Return Valve
• Also known as the “Check Valve” which
allows a signal to flow through the device in
one direction and in the other direction
blocks the flow.
 Shuttle Valve
This device performs the logic
“OR” function with two inputs and an
output.

Dual Pressure Valve

This device performs the logic
“AND” function with two inputs and an
output.
 Shuttle Valve /
Dual Pressure Valve
 Quick Exhaust Valve
• Valves which are used where the
volume to be exhausted exceeds the
exhaust capacity of the supplying
valve.
• Normally used when a fast exhaust
is required to achieve a fast switch
back.
Quick Exhaust Valve
 One Way Restrictor/
One Way Flow Control
• A combination of
non-return valve
and a flow
regulator.
• Controls the flow
of air from the
input side to the
output side.
 III. Pressure Control
Valve
• It controls the
pressure of the air
flowing through
the valve or
confined in the
system controlled
by the valved.
Groups of Pressure Valve
• Pressure Regulating valve
• Pressure Limiting Valve
• Pressure Sequence valve
 Pressure Regulators
• These valves reduce the output
pressure where there is varying
higher input pressure. The control
pressure is sensed at the output of
the valve.
 Pressure Relief(limiting)
Valve
• The pressure in a
system is set and
restricted by
these valves. The
control pressure is
sensed at the input
of the valve
Uses of Pressure Relief
Valves
• Safety Valves
– A pressure relief valve is termed a
safety valve when it is attached to the
pump, for example, to protect it from
overload. The valve setting is fixed at
the maximum pump pressure. It only
opens in case of emergency.
Uses of Pressure Relief
Valves
• Counter Pressure Valves
– These counteract mass moments of
inertia with tractive load. The valve
must be pressure-compensated and the
tank connection must be loadable.
Uses of Pressure Relief
Valves
• Brake Valves
– These prevent pressure peaks, which
may arise as a result of mass moments
of inertia on sudden closing of the
directional control valve.
Pressure Sequence Valve
• Used if a pressure dependent signal is
required for the advancing of a control
system. When the applied control signal
reaches the set pressure, the 3/2 way
valve incorporated at this point is
actuated. Conversely, the valve reverses, if
the control signal falls below the set
pressure.
 Combinational Valves

• Components of different control

groups were combined into the body
of one unit with the features,
characteristics and construction of a
combination of valves.
 Combinational Valves
The following units can be defined as
combinational valves:
• Time Delay valves – for the delay of signals
• Air control blocks – for the execution of
individual and oscillating movements using
double-acting cylinders.
 Combinational Valves
• 5/4 way valve – for the stopping of
double acting cylinders in any position
• Air-operated 8 way valve – for the
control of feed units
• Pulse generator – for the execution
of rapid cylinder movements
 Combinational Valves
• Vacuum generator with ejector – for
pick and place applications
• Stepper Modules – for sequential
control tasks
• Command Memory modules – for
startup with signal input conditions
 Time Delay Valve

• Delay-On (Normally Closed Position)

• Delay-Off (Normally Open Position)

Coordinated Motion
Coordinated Motion
Step Diagram
Methods of Actuation
 Combinational Devices
• Pressure Sequence Valve
• Time Delay Valve
Pressure Sequence Valve
• Used if a pressure dependent signal is
required for the advancing of a control
system. When the applied control signal
reaches the set pressure, the 3/2 way
valve incorporated at this point is
actuated. Conversely, the valve reverses, if
the control signal falls below the set
pressure.
Pressure Sequence Valve
 Time Delay Valve
• Time delay valve is the combination of a one way
flow control valve, a reservoir and a 3/2 way
directional control valve. Depending on the setting
of the throttling screw, a greater or lesser
amount of air flows per unit of time into the air
reservoir. When the necessary control pressure
has built up, the valve switches to through flow.
This switching position is maintained for as long as
the control signal is applied.
Time Delay Valve
 Sample Problem No. 1
A single acting cylinder of 25mm
diameter is to clamp a component
when a pushbutton is pressed. As long
as the pushbutton is activated, the
cylinder is to remain in the clamped
position. If the push button is
released, the clamp is to retract.
Answer
Sample Problem No. 2
A double acting cylinder is to
advance when a pushbutton is
operated. Upon release of the
pushbutton the cylinder is to
retract. The cylinder is 250mm
diameter and consumes a large
volume of air.
Answer
Sample Problem No. 3
The piston rod of a double acting cylinder is
to advance when a 3/2 way push button valve is
actuated manually. The cylinder is to remain
advanced until a second valve is actuated. The
signal of the second valve can only take effect
after the first valve has been released. The
cylinder is to remain in the initial position until a
new start signal is given. The speed of the
cylinder is to be adjustable in both directions.
Answer
 CONTROL PROBLEMS

• A single acting cylinder of 25mm diameter is to clamp a

component when a pushbutton is pressed. As long as the
pushbutton is activated, the cylinder is to remain in the
clamped position. If the push button is released, the clamp
is to retract.

• A single acting cylinder with a large piston diameter is to

clamp a workpiece following actuation of a pushbutton. The
cylinder is to retract once the pushbutton is released.

• A double acting cylinder is to extend when a pushbutton is

operated. Upon release of the pushbutton the cylinder is to
retract. The cylinder is of a small bore (25mm diameter)
requiring a small flow rate to operate at the correct speed.
• A double acting cylinder is to advance when a pushbutton is operated.
Upon release of the pushbutton the cylinder is to retract. The
cylinder is 250mm diameter and consumes a large volume of air. The
speed is to be adjustable.

• The piston rod of a double acting cylinder is to advance when the 3/2
way roller level valve is actuated and the pushbutton of the 3/2 way
valve is actuated. If either of these is released, then the cylinder is
to return to the initial position.

• A double acting cylinder is to advance if one of two pushbuttons is

operated. If the push button is then released, the cylinder is to
retract. A double pilot valve should be fitted for the control of the
cylinder. If the cylinder is to retract on reaching its fully extended
position, roller level valves should be used as limit switches to confirm
that this position has been reached.