Trainor’s Training

Pneumatics Technology

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Pneumatics Technology
Training Objectives

The participant’s should be able to:

- learn the operation and function of each pneumatic components

- learn how to read and apply pneumatic symbols
- learn how to create and interpret a pneumatic circuit diagram
- perform an actual/hands on wiring using the available pneumatic system

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Safety in pneumatic systems  Check all equipment carefully for damage. Use only flawless parts.

 Always keep the working area of the unit clean and orderly, in
 Observe specifications included in the data sheets for the individual order to avoid danger from dirt.
components, and in particular all safety instructions.

 Mount all of the components securely onto the slotted profile plate.
Optimum safety is achieved
 Do not exceed the maximum permissible pressure of 600 kPa (6 bar). in the workplace

Equipment Safety  Switch compressed air supply off before dismantling the circuit.

 Pneumatic circuit setup:

Connect the devices with plastic tubing with an outside diameter of 4 or 6 mm.
Push the tubing into the push-in connector as far as it will go.

 Do not activate compressed air until all of the tubing connections

have been completed and secured.
Users Safety
 Do not disconnect tubing while under pressure.

 Danger of accident due to tubing slipping off!
– Use shortest possible tubing connections.
– In the event that tubing slips off:
Switch compressed air supply off immediately.
 Danger of injury when switching compressed air on!
Cylinders may advance and retract automatically
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Basic Pneumatics Training “enables you to teach tomorrow’s
industrial standard today”
 covers basic introduction in
pneumatic control technology Signal
Flow
 Structure, function and application of single-
acting and double-acting cylinders
Pneumatic
System Drive
 Application and function of 3/2 and 5/2-way
valves Structure Components
 Methods of actuation of directional control
valves Pneumatic
 Analyzing circuits System
 Pressure-dependent control systems
Pneumatic Control
 Distinguishing flow control methods and using
Symbols Elements
them as intended

 Explaining and building latching circuits

Energy
 Logic operations: explaining and implementing Supply
AND/OR/NOT operations

 Function and application of limit switches

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Structural and signal flow of pneumatic systems
 Pneumatic systems consists of an interconnection of different groups of elements.

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Pneumatic Energy Supply Air Compressor
Components:
How to use?
 Pump
 Motor pump
 Air tank / receiver
Energy 

Pressure Relief Valve
Drain valve
Supply  Quick fix plug/connector
 Selector type On/Off switch

Energy  Pressure regular w/ gauge

Supply
Function
Symbols
 takes air at atmospheric pressure as input
and delivers high pressure air as output
 pressure is restricted to the preset operating
equipment rating:220 V, 60 Hz
pressure

Compressor Compressor, Adjustable Compressed air supply

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Pneumatic Control Elements Directional Control Valves
 controls the passage of air signals by generating, cancelling
or redirecting signals.

 to control the direction of flow in the pneumatic circuit

 can be used to start, stop, and to change the fluid flow in a

Control pneumatics system

elements  used to control drive components like cylinders and motors

as well as used in pneumatic control circuits

 A device that controls Drive

components motion. The valve is described by:

 Number of ports or openings (ways): 2-way, 3-way, 4-way, etc.

 Number of positions: 2 positions, 3 positions, etc.
 Methods of actuation of the valve: manually actuated,
mechanically actuated, pneumatically actuated, electrically actuated.
 Methods of return actuation: Spring return, air return, etc.

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Switching Symbols for Valves
 The valve switching position is shown by a square.

 The number of squares corresponds to the number of switching positions.

 Lines indicate the flow paths, arrows indicate the direction of flow.

 Closed ports (blocks) are shown by two lines drawn at right angles to one another.

 The connecting lines for supply and exhaust air are drawn outside the square.
Methods of Actuation
 The directional control valve can be actuated by:
Pneumatic Control Elements

Directional  5/2-way single-pilot valve,

pneumatically actuated in one direction,
Control valves spring return

direct pneumatic actuation

 5/2-way double-pilot valve,

pneumatically actuated in both directions

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Pneumatic Control Elements

 3/2-Way-Panel mounted with

Directional Pushbutton Actuator,
push button normally closed, spring return
Control valves
manual pneumatic actuation

 3/2-Way- Panel mounted Valve

with Pushbutton Actuator,
normally open, spring return

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Pneumatic Control Elements

 3/2-way valve with selector switch,

Directional normally closed, spring return
selector
Control valves
manual pneumatic actuation

 5/2-Way- Panel mounted Valve

with selector switch, spring return

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Pneumatic Control Elements

Directional
selector
Control valves
manual pneumatic actuation  3/2-way valve, normally closed,
magnetically actuated

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Final Control Elements

Other pneumatic valves:

Other  Shuttle valve (OR element)
Pneumatic
valves  Dual pressure valve (AND element)

 Non-return valve (check valve)

 allows air stream to be controlled for the proper  Quick exhaust valve
activation of the drive components.
 Pressure sequence valve
 these are additional components that modifies
some characteristics of drive components to obtain
 One-way flow control valve
desired responses (eg. slow extension speed, fast
retraction)
 Pneumatic timer, normally closed
Energy supply

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Final Control Elements
Dual pressure valve (AND function) Shuttle valve (OR
function)

Other Control
valves
 If compressed air is applied to inlet P 1,
 Compressed air flows through only if
signals are applied to both inlets. the ball seals off inlet P2 and the air
flows from P1 to A. Alternatively, the
air flows from P2 to A when P1 is
closed.

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Final Control Elements
Pressure sequence valve
Quick-exhaust valve
2

1
1/ 3

  2 

Other Control  used to increase the piston speeds in cylinders

valves  enables lengthy return times to be avoided, particularly
with single-acting cylinders

 valve acts is where the pressure is set against the spring.

One-way flow control valve If the pressure exceeds that set on the spring, the valve
opens
2

 the air flow is throttled in one direction only, a check

valve blocks the flow of air in the bypass leg and the air
can flow only through the regulated cross-section. 12 1 3

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Non-return valve / Check valve
 allow fluid flow in only one direction
 used as a bypass device

Variants of Check Valve

Check Valve, Unloaded

Check Valve, Spring-Loaded 1

1/ 3

2 3

Check Valve, Spring-Loaded, piloted   2 

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Additional Control Elements

Pneumatic timer, normally closed

 time required for pressure to build up in the air

reservoir is equal to the control time delay of the
Other Control valve.

valves

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Pneumatic Drive Components

Actuators

 an output device for the conversion of supply energy

Actuator into useful work

 the powering elements in a pneumatic control system

Control components  devices at the end of the control chain. They convert the
control signal into work (execution of instruction)

 device that converts compressed air into mechanical

motion

Energy Supply

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Pneumatic Drive Components

Linear
Actuator
Single-acting cylinder

 perform linear work in one direction only,

the other direction is performed via spring

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Pneumatic Drive Components

Linear
Actuator
Double-acting Cylinder w/
End-position Cushioning

 perform linear work in both directions

(forward stroke and return stroke)

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Designing Pneumatic Circuit
Listing in
Chronological
 understand the different methods of representing the
order
Pneumatic working sequence.
Displacement Tabular listing
time diagram

Pneumatic
Sequencing
Circuits
Displacement Vector diagram
Step Diagram

Circuit Diagram
Representation

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Designing Pneumatic Circuit

Circuit Diagram
Representation

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Numbering or elements

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Example Application

Sample 1 Sample 2

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Designing Pneumatic Circuit

Tabular listing

Tabular
listing

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Designing Pneumatic Circuit
Vector equivalent

Listing the Pneumatic working Cylinder 1

sequence in chronoligical order Cylinder 2
1. Cylinder 1 - clamps the sheetmetal component Cylinder 3
Vector 2. Cylinder 2 - first bending operation Cylinder 3
3. Cylinder 3 - second bending operation
Diagram 4. Cylinder 3 - travels with bending die into initial
Cylinder 4
position Cylinder 4
5. Cylinder 4 - punches 4mm hole Cylinder 2
6. Cylinder 4 - travels into initial position Cylinder 1
7. Cylinder 2 - travels with bending die to initial position
8. Cylinder 1 - unclamps finished sheetmetal component
Travel out
Travel in

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Designing Pneumatic Circuit

Listing the Pneumatic working

sequence in chronoligical order Cylinder 1 +
1. Cylinder 1 - clamps the sheetmetal component Cylinder 2 +
Abbreviated 2. Cylinder 2 - first bending operation Cylinder 3 +
3. Cylinder 3 - second bending operation
notation 4. Cylinder 3 - travels with bending die into initial Cylinder 3 -
position Cylinder 4 +
5. Cylinder 4 - punches 4mm hole
Cylinder 4 -
6. Cylinder 4 - travels into initial position
7. Cylinder 2 - travels with bending die to initial position Cylinder 2 -
8. Cylinder 1 - unclamps finished sheetmetal component Cylinder 1 -

Travel out +
Travel in -

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Designing Pneumatic Circuit

Displacement
Step Diagram

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Designation using alphabetic characters

A0 A1

A, B, C, ….. allocated to the working elements

A1, b1, c1, … allocated to the signal elements in the
forward end position
A0, b0, c0, … allocated to the signal elements in the
rear end position

A+ B+ C+ C- D+ D- B- A-

124

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Analyzation and Application of Pneumatic Circuit Symbols
How to apply?

Control of a Single-acting cylinder Indirect control of a Double-acting cylinder Control with Shuttle Valve
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Do you have any question?

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Let’s do the Practical Exercises

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Electro-pneumatics
 control system by the mean of air pressure whereby air pressure,
controlled by an electric current.

 electro means electrical and pneumatic which means pressurized air.

 a pneumatic control system where air pressure and direction of valve

are controlled by an electrical current.

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Electrical signal control section

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Basic Electrical devices commonly used
in controlling fluid power systems

 Signal input, electrical / Push Button Switch

 Momentary Switch / PB
 Detent Switch / PB

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Basic Electrical devices commonly used
in controlling fluid power systems

 Relay, three-fold

 control on/off of various outputs sequences using contacts

 use an electromagnet (coil) to operate their internal

mechanical switching mechanism (contacts)

 used for controlling multiple circuits

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Basic Electrical devices commonly used
in controlling fluid power systems

 Limit switch, electrical, right-actuated

 a switch operated by the motion of a machine part or

presence of an object

 detect or sense the presence of an object or to monitor

and indicate whether the movement limits of that
object have been exceeded.

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Basic Electrical devices commonly used
in controlling fluid power systems

 Proximity sensor, electronic, with cylinder mounting

(Magneto-resistive proximity sensor, magnetically operated)

 used in proximity detection of magnetic materials.

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Basic Electrical devices commonly used
in controlling fluid power systems

 5/2-way double solenoid valve with LED

 electromagnetic device used to generate magnetic field and

therefore a resulting mechanical pull or push (usually linear motion).
 composed of a long thin loop of conductive wire wrapped around a magnetic
core and generates a magnetic field around it when an electric current is
passed through the conductive wire

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Basic Electrical devices commonly used
in controlling fluid power systems

 Pressure sensor with display

 use to measure the pressure of the compress air in the system

 typical application include:

• Service units for compressed air networks

• Monitoring of clamping force when machining workpieces

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Basic Electrical devices commonly used
in controlling fluid power systems

 Preset counter, electronic

 Used when counting applications is needed like:

 counting bottles passing through the conveyor belt

 counting the number of cars entering and leaving the

parking area to determine if the parking area is full or not

 counting the number of workpiece transferred and

delivered

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Basic Electrical devices commonly used
in controlling fluid power systems
 Time Relays

 used when timing applications is needed like:

 delaying the start of a machine upon actuation of a start pushbutton

 delaying the turning off of machines upon actuation of a stop

pushbutton
Two types of time relay
Ex. OVEN
MACHINE TOWER LIGHTS
 Pull-in delay (ON delay)
STOP LIGHTS
URINALS

 Drop-out delay (OFF delay)

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 Sensor wiring configuration
Sensor Connection technology
BN(1)
+24V DC
PNP normally closed
BK(4)
L
BU(3)
0 V

BN(1)
+24V DC

 3 – wire technology
BK(4) PNP normally closed
L
BU(3)
0 V

Two leads for supply power BN(1)

+24V DC
NPN normally open
BK(4)

Third lead as signal output BU(3)

L

0 V

Load L connected ground (PNP) or positive pole (NPN)

BN(1)
+24V DC
BK(4) NPN normally closed
L
BU(3)
0 V

 4 – wire technology 1
2.3F
our
-Wi
r eTe
chn
olog
y

BN(1)
Usually has an antivalent switching function (changeover contacts) BK(4)
+24V DC
L PNP normally op
WH(2) closed contacts
BU(3)
0 V

BN(1) +24V DC
BK(4) L
NPN normally op
WH(2) closed contacts
BU(3)
0 V

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Basic Electrical devices commonly used
in controlling fluid power systems
 Capacitive Sensors / Proximity sensor, capacitive, M12

 Can detect various material types either insulative or conductive materials

 Can detect objects inside another object because of dielectric constant
values
 Can detect even the darkest color (a problem with optical sensors)
 Ability to distinguish material according to type (via dielectric constant
value)

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IEC 60617 & EN 81346-2: For Electro-technical Diagrams
 IEC 60617 contains graphical symbols for use in electrotechnical diagrams
 EN 81346-2 for letter designations for use industrial systems and installations

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IEC 60617 & EN 81346-2: For Electro-technical Diagrams
 IEC 60617 contains graphical symbols for use in electrotechnical diagrams
 EN 81346-2 for letter designations for use industrial systems and installations

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IEC 60617 & EN 81346-2: For Electro-technical Diagrams
 IEC 60617 contains graphical symbols for use in electrotechnical diagrams
 EN 81346-2 for letter designations for use industrial systems and installations

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IEC 60617 & EN 81346-2: For Electro-technical Diagrams
 IEC 60617 contains graphical symbols for use in electrotechnical diagrams
 EN 81346-2 for letter designations for use industrial systems and installations

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Basic rules in designing electro-pneumatic circuit
A S1 S2 B S3 S4

STEPPER CONTROL METHOD 4 2

4 2

Y1 Y2
Y3 Y4

Sequence Control Design Procedure:

5 3
5 3
1
1

1. Create sequence Diagram/Pattern +24V

+24V

2. Determine the Control Circuit and Power Circuit S5 S2 S4 S1 K1 K2 K3 K4

3. In the control circuit, each step in the sequence has its own
STEP RELAY that is activated by the corresponding input/s. S3

4. Do self-holding to each relay except on the last sequence

5. Prepare for the next sequence

K1 K2 K3 K4 Y1 Y3 Y2 Y4

6. Last relay is used to reset the whole circuit

0V

0V
7. Energized or de-energized the output(s)
A+ B+ A- B- A+ B+ A- B-
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Analyzation and Application of Pneumatic Circuit Symbols How to apply?

4 2
4 2 4 2 4 2
Y1
Y1 Y1
5 1 3 5 1 3 5 3 Y1 Y2
1 5 3
1

1 3

+24V +24V

+24V S1 S2 S3 K1 K2

S1 S1 K1 K1
S1
K1 K2 Y1 Y2
0V

+24V

S1 S2 S3 K1 K2

Y1
K1 Y1 Y2
0V 0V 0V
Y1 Y2 Y1 Y2

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Do you have any question?

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Let’s do the Practical Exercises

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