Factory Automation

Presents……...
International Training
WHAT IS PNEUMATICS?
The use of Compressed Air Technology to do work.
COMPRESSED AIR
From the atmosphere, air is reduced in volume by
compression, thus increasing its pressure
(compacted form of energy).
It is mainly used to do work by being allowed to

expand to a lower pressure when acting on a piston
or a vane.
WHAT CAN PNEUMATICS DO?
The applications for compressed air are limitless, from
low pressure (vacuum) to medium pressure (6 bars),
high forces required, etc.
General Applications are:
Feeding, lifting up of objects
Clamping, stamping, cutting
Forming of
components
Packaging
Transferring of materials (pick and place)
Sorting of parts
Bus door system
Spray painting
Robots
APPLICATION OF COMPRESSED AIR
Power Air
Air is used to drive drills, air motors, chucks, presses
& machines. Power air must be free from liquid
(water & oil) and solid particles.
Process Air
Air is used to mix or aerate chemicals, food ingredients,
& in other operations where air contacts with products
or ingredients.
Process air is sufficiently cleaned to avoid
contamination of ingredients or products and to
prevent undesirable side reactions as in some chemical
applications.
Instrument Air
Air is used to actuate instruments or controls which

initiate, modulate, terminate or otherwise direct
machine process.
Air quality is critical in the proper functioning of

precision instruments and controls. Even microscopic
traces of oil, dirt and moisture will affect their
reliability. Instrument air is commonly dried to
remove water condensates, filtering to remove solids
and oil essential.
WHY USE COMPRESSED AIR?
ADVANTAGES:
- Availability
Unlimited quantity and air is free
- Storage
Easily stored in large volume by receiver
- Low Cost Automation
Pneumatic components are easy to fit to
provide extensive automated systems with low
cost and simple control
- Choice of Movement
Linear or rotary movement at high speed or
variable slower operation speed
- Reliability
Pneumatic components have long working life
thus high system reliability
- Environmentally Clean
Clean, non-toxic, no pollution (food, textile,
leather industries, etc.)
- Resistance to Environment
Unaffected by high temperature, dusty and
corrosive environment
- Safety
Overload safe & explosion proof
- Ease of Maintenance
DISADVANTAGES:
- Compressed air is not cheap to produce

- Purification is required
- Noise pollution
- Comparatively low force due to relatively
low pressure(economical range up to 25 KN)
- Speed control is less accurate
- Intermediate positioning is not easily
obtained
PNEUMATIC APPLICATIONS:
BASIC AIR LINE SYSTEM
Compressor Aftercooler Air Tank
Piping Air Dryer Main Line

Filter
Air Service Working

Unit (FRL) Machine
COMPRESSOR TYPES USED
IN PNEUMATIC SYSTEMS
DISPLACEMENT COMPRESSOR
RECIPROCATING ROTARY
DIAPHRAGM PISTON SCREW VANE
RECIPROCATING COMPRESSOR
SINGLE STAGE PISTON COMPRESSOR
It is generally used in systems requiring

compressed air in the 3 - 7 bar range
TWO STAGE PISTON COMPRESSOR
Air taken in at atmospheric pressure is

compressed in two stages to the final pressure
AFTERCOOLER
After final compression (compressor), the air will
be hot and, when cooling, will deposit water in
considerable quantities in the pipeline which
should be avoided. The most effective way is to
install an aftercooler immediately after the
compressor.
FUNCTIONS
- to remove water condensation
- to remove compressor oil
AIR COOLED AFTERCOOLER
WATER COOLED AFTERCOOLER
AIR RECEIVER
An air receiver is a pressure vessel of welded

steel construction, installed horizontally or
vertically directly downstream from the
aftercooler to receive the compressed air.
FUNCTIONS
- to store sufficient compressed air to meet

heavy
demands in excess of compressor capacity
- to dampen the initial pulsations in the air flow
- to minimize frequent “loading” and “unloading”

of the compressor
- to provide additional cooling to precipitate oil
and moisture carried over from the aftercooler,
before the compressed air is distributed further
MAIN LINE FILTER
AIR HUMIDITY
Atmospheric air always contains a percentage of
water vapour. The amount of moisture present
will depend on the atmospheric humidity and
temperature.
When atmospheric air cools, it will reach a

certain point at which it is saturated with
moisture, this is known as the “Dew Point”. If
the air cools further, it can no longer retain all
the moisture and the surplus is expelled as
miniature droplets to form a “Condensate”.
TYPES OF AIR DRYER
• Absorption (Deliquescent) Dryer
- Drying agents are
dehydrated chalk,
magnesium chloride,
lithium chloride, or
calcium chloride
- Pressure dew point of
5oC at 7 bar is possible
- Low initial and operating
cost, but the inlet
temperature must not
exceed 30oC because the
chemicals involved are
highly corrosive
• Adsorption (Dessicant) Dryer
- Chemicals such as
silica gel or activated
alumina in granular
form are used in this
type of dryer
- Extremely low dew points
are possible with this
method, say - 40oC
- Initial & operating costs
are comparatively high
but maintenance cost
tends to be low
• Refrigerated Dryer
- This is a mechanical
unit incorporating a
refrigeration unit and
two heat exchangers
- Dew point of 2oC is
possible
- Inlet temperature
may be up to 60oC
but it is more
economical to pre-
cool to run at lower
inlet temperatures
As a general rule, the cost of drying compressed air
may be 10 - 20% of the cost of compressing air.
PIPING SYSTEM
• Ring Main
Compressed air can be fed from two sides to a point of

high consumption, this will minimize pressure drop
Water is driven in any direction and sufficient water

take-off with auto drains should be provided
• Dead End Line Main
The pressure at the last few points are weaker due to

high air consumption in the front points
This lay-out is used where few take-off points are

required
AIR SERVICE UNIT (F.R.L. Unit)
MICRO FILTER
- Micro filter is used
where contamination
by oil vapour is
undesirable
- Dust is trapped within
the micro filter element,
the oil vapour & water
mist is converted into
liquid forming droplets
to be collected at the
bottom of the bowl
- Can eliminate dust
particles whose size is
greater than 0.3um
SUB-MICRO FILTER
A sub-micro filter will remove virtually all oil and

water and also fine particles down to 0.01 of a
micron, to provide maximum protection for
pneumatic precision measuring devices,
electrostatic spray painting, cleaning and drying
of electronic assemblies, etc.
The principle of operation is the same as a micro
filter, but its filter element has additional layers
with a higher filtration efficiency.
FILTER SELECTION
The size of air filter that is required for a
particular application is dependent on two
factors:
- the maximum flow of compressed air used by
the pneumatic equipment
- the maximum acceptable pressure drop for the
application
Manufacturers provide flow/pressure diagrams

to enable correct sizing.
It should be noted that using a standard filter

for the application may not separate as
efficiently because of a lower flow velocity
STANDARD REGULATOR
Pressure regulators may

have a piston or diaphragm
construction to balance the
output pressure against an
adjustable spring force.
PROPORTIONAL LUBRICATOR
DEFINITION OF 7 DEGREES OF FILTRATION
SENSORS
- input signal elements
- pushbuttons, limit switches, rollers,
levers, foot pedals, selector switches,
key selectors, etc.
- can be classified into manual and
mechanical method of operation
- comes in monostable or bistable type
MANUAL OPERATION
Monostable Type
MANUAL OPERATION
Bistable Type
MECHANICAL OPERATION
POPPET VALVES
Flow through a poppet valve is controlled by a
disc or plug lifting at right angles to a seat
with an elastic seal
ADVANTAGES
 A short lift gives maximum flow offering
fast response and rapid cycling capabilities
 Short stroke results in minimum wear to
give maximum working life and less
maintenance
 Sealing effect is good
 Simple construction results in low cost
POPPET VALVES
SPOOL VALVES
CHARACTERISTICS
 Offers greater versatility in the number of
ports, positions and center options
 Balanced construction so that the actuating
force is unaffected by fluctuations in
pressure
 Often can be connected for normally open
or normally closed operation
 Simple construction results in low cost
VALVE TYPES
DIRECTIONAL CONTROL VALVES
POPPET VALVES SLIDING VALVES

(Elastic Seal)
SPOOL PLANE SLIDE ROTARY

VALVES VALVES VALVES
(Elastic/Metal (Metal Seal) (Metal Seal)
Seal)
DESCRIPTION OF VALVES (DCV)
Directional Control Valves are described in terms of:
- Number of ports / Number of switching positions
- Method of Operation
- manual, mechanical, electrical, or air
- Method of Reset
- spring, air, or electrical(solenoid)
- Normal Position
- normally open or normally closed
- Ports Designation based on ISO
- ISO 1219 (Japanese), ISO 5599 (European)
No. of ports
SYMBOLIC REPRESENTATION
No. of switching position
where: Flow path

Switching position
Blocked port
METHOD OF OPERATION (left side)

Manually - pushbuttons ; ;
Mechanically - limit switches ; rollers ; levers ; ;
Pneumatically - air ;
Electrically - solenoid ;
METHOD OF RESET (right side)
Spring -
Air -
Solenoid -
PORTS DESIGNATION (based on ISO)
ISO 1219 ISO 5599

(Japanese) (European)
Supply Port P 1
Output Ports A, B 2, 4
Exhaust Ports R, S 3, 5
Pilot Ports Y, Z 12, 14
NORMALLY CLOSED
At normal (not operated) position, air passage
between inlet and outlet is closed
A
P R
NORMALLY OPEN
At normal (not operated) position, air passage
between inlet and outlet is open
A
P R
MONOSTABLE VALVES
Spring returned valves are monostable. They have

a defined preferred position to which they
automatically return (Normal Position)
BISTABLE (Memory) VALVES
A bistable valve has no preferred position and
remains in either position until one of its two
impulse signals are operated
A B
R P S
Double air piloted valve
A B
R P S
Double solenoid valve
SPOOL VALVE (Metal Seal)
3/2 WAY MICRO POPPET VALVE
(Mechanically Operated)
3/2 WAY NC POPPET VALVE
(Mechanically Operated)
5/2 WAY PLANE SLIDE VALVE
(Memory Valve)
5/3 WAY PRESSURIZED CENTER VALVE
5/3 WAY CLOSED CENTER VALVE
5/3 WAY OPEN CENTER VALVE
POWER LEVEL
ACTUATORS
- Converts the pneumatic energy to kinetic energy
(linear or rotary motion)
e.g. - single acting cylinder
- double acting cylinder
- air motor
- rotary
-actuator
impulse ejector
- vacuum ejector with suction pad, etc.
POWER VALVES
- Controls the movement of actuators
e.g. - directional control valves
SINGLE ACTING CYLINDER
DOUBLE ACTING CYLINDER
(DOUBLE ROD)
Application of Double Rod Cylinder
LOCKING CYLINDER
TANDEM CYLINDER
MULTI POSITION CYLINDER
(3 POSITIONS)
RODLESS CYLINDER
(SPACE SAVING)
(SHORT STROKE)
SLIDE UNIT
AIR CHUCK
(GRIPPER)
SLIDE UNIT
(PICK & PLACE)
CYLINDER MOUNTING
CYLINDER CONSTRUCTION
ROTARY ACTUATORS
LIMITED ANGLE OF ROTATION

- Rack and pinion type rotary actuator
- Vane type rotary actuator
CONTINUOUS ROTATION
- Vane / Turbine air motors
ROTARY ACTUATOR
(RACK & PINION)
ROTARY ACTUATOR
(RACK & PINION)
PNEUMATIC INDICATOR
SHUTTLE VALVE
(OR VALVE)
TWO PRESSURE VALVE
(AND VALVE)
FLOW CONTROL VALVE
CHECK VALVE
A check valve allows free air flow in one

direction and seals it off in the opposite
SPEED CONTROLLER
QUICK EXHAUST VALVE
This component permits a maximum

outstroking piston speed by exhausting the
air directly at its port with a great flow
capacity to atmosphere, instead of through
the directional valve and air tubing, so
increase the “normal” piston speed
TIME DELAY VALVE
BASIC PNEUMATIC CIRCUITRY
Working Element
A B
Control Element
R P S
Signal Element
EXAMPLE
Using a rotary indexing table, parts are to be indexed out in
sequence to the next operation. By pressing a START
pushbutton, the rotary table is indexed by the oscillating
piston rod of a cylinder via a stop pawl. When the STOP
pushbutton is pressed, this drive is switched off.
BASIC ELECTRO-PNEUMATIC SYSTEM
POWER LEVEL
(Pneumatic Actuators)
CONVERTERS
(Electro-Pneumatic Converters)
LOGIC LEVEL
(Electrical Components)
SIGNAL INPUT LEVEL

(Electrical Components)
ENERGY SUPPLY
(Electrical Supply)
HYBRID SYSTEM
ELECTRO-PNEUMATIC SYSTEMS ARE

“HYBRID”
(A mixture of two different technologies)
HARD-WIRE SYSTEM
This system requires the physical point to point
connections between each individual input devices
and output elements.
+24V Start 0V
Stop
R
R
R Lamp
We are working with 24 V DC
supply, is this voltage
DANGEROUS ? ? ? ?
EFFECTS OF ELECTRICAL
CURRENT ON HUMAN
0.3 mA SENSITIVITY EFFECT

1 mA FRIGHT SHOCK
10 mA MUSCULAR CRAMPS
30 mA LOSS OF CONSCIOUSNESS
50 mA HEART FLUTTER
(may lead to death)
ELECTRO-PNEUMATIC
CONTROL PANEL
GENERAL REPRESENTATION
ELECTRICAL PNEUMATICS
Voltage Pressure
(+24V) (6 bars)
Current Flowrate
(4 mA) (10 l/min)
Resistance Friction
PUSHBUTTON
(Normally Open)
PUSHBUTTON
(Normally Closed)
PUSHBUTTON
(Change-over Contact)
ROCKER SWITCH
(Latching Contact)
LIMIT SWITCH
REED SWITCH
REED SWITCH
REED SWITCH
ADVANTAGES
 Quiet in operation
 Lifetime is much longer than a mechanical
switch (relay)
 Fast response time (e.g. ~ 1.2 ms)
 Maintenance is not required
 Reed contact free from corrosion and
contamination
REED SWITCH
DISADVANTAGES
 Allowable current/voltage that can be

switched is limited. Otherwise, burn out of
contact may arise
 High contact wear (arcing) if the
inductance of the connected circuit is
relatively high
 For an inductive load, contact protection
circuit is required
REED SWITCH
Most of the reed switches are provided with an
LED indicator and an electronic circuit
This circuit serve various purposes:
 Contact protection of its own reed switch
 Providing adequate voltage for the LED
indicator
 Surge voltage protection of the electronic
circuit (DC types only)
PROXIMITY SENSORS
 Inductive Sensor
 Capacitive Sensor
 Optical Sensor
 Cylinder Switches
 Reed Switch
 Static Switch
PROXIMITY SENSORS
(Non-contact Sensing)
The sensing distance depends on:
 Type and material of the sensing object

e.g. Steel, copper, plastic, water, paper, etc.
 Sensing head size of the sensor

e.g. M8, M12, M18, M30, etc.
PROXIMITY SENSORS
(Non-contact Sensing)
ADVANTAGES
 High switching frequency
 No contact bounce
 No moving parts, contact wear or sparks
and free from corrosion
 High degrees of environmental protection
available
 Immune to the effects of vibration & shock
PROXIMITY SENSORS
(Inductive/Capacitive/Optical)
NOTE
The correct polarity of the applied

voltage/current is important for proper
function of proximity sensors
Inverse Polarity Protection Circuitry protects

the proximity sensor against inversion of the
supply voltage
PROXIMITY SENSORS
(Inductive)
PROXIMITY SENSORS
(Capacitive)
PROXIMITY SENSORS
(Capacitive)
Capacitive proximity sensors senses almost all

kinds of objects
Metallic or non-metallic which has a good
conductibility or a good dielectric constant can
be detected by a capacitive proximity sensor
e.g. water, oil, glass, plastic, paper, etc.
PROXIMITY SENSORS
(Optical-Reflective)
PROXIMITY SENSORS
(Optical-Retroreflective)
PROXIMITY SENSORS
(Optical-Separate)
PROXIMITY SENSORS
(Inductive/Optical)
3 - Wire 4 - Wire
+ +
(NO) (NO)
(NC)
- -
CONNECTION DIAGRAM (NPN)
LADDER DIAGRAM
 JIC +24V + - 0V
R1
R1
 DIN +24V
R1 R1
+
-
0V
CONNECTION DIAGRAM (PNP)
LADDER DIAGRAM
 JIC +24V + -
R1
R1
0V
 DIN +24V
R1
+
-
R1
0V
RELAY
APPLICATION EXAMPLE
(Relay)
RELAYS
ADVANTAGES
 Wide range of operating voltages

e.g. 6, 12, 24, 50, 110, 220, 240 VAC
6, 12, 24, 48, 110 VDC
 High vibration and shock resistance
 Not much affected by ambient temperature
e.g. - 55 oC to 70 oC
 A number of independent circuits can be
switched at a time
RELAYS
DISADVANTAGES
 Noise in operation
 High contact wear from arcing
 Contact protection circuit required

 Limited operating speed
e.g. 15 ~ 30 ms max
 Contacts are affected by dirt and dust
RELAYS
FUNCTIONS
 Memory function where an impulse signal
is converted to a long and lasting signal
 Multiplying contact from one (to energize the
coil) to any reasonable number of contacts
 Power amplification whereby a small input
signal is able to drive high output signal
 Changing from a normally closed to
normally open contact (Inversion)
 Converts a lasting signal to an impulse
signal
SOLENOID
2/2 NC SOLENOID VALVE
(Spring Return, Poppet Type)
3/2 NC SOLENOID VALVE
(Spring Return, Poppet Type)
5/2 DOUBLE SOLENOID VALVE
(Indirect Solenoid, Pilot Operation)
GUIDELINES IN DRAWING
CIRCUIT DIAGRAM
1. JIC - Japanese Industrial Control
- Power lines are drawn as two parallel vertical lines
- Signal flow is from left to right
DIN - Deutsch Industrie Norm
- Power lines are drawn as two parallel horizontal
lines
- Signal flow is from top to bottom
2. Control components should be drawn in the
initial rest position
GUIDELINES IN DRAWING
CIRCUIT DIAGRAM
3. Working line should be drawn in horizontal or
vertical lines
4. If possible, overlapping (crossing) of working
line should be avoided
5. Lines crossing or lines connection should be
clearly specified
Lines crossing Lines connection
CIRCUIT DIAGRAM LAYOUT
LADDER DIAGRAM
R1 0V
 JIC +24V
R1
 DIN +24V
R1
R1
0V
ELECTRICAL TIMER
There are two main types of timers:
- Slow-operating relay (energizing delay)

- Slow-releasing relay (de-energizing delay)
ELECTRICAL COUNTER
There are two main types of timers:
- UP counter (counting is done in ascending
manner)
- DOWN counter (counting is done in
descending manner)
CONTROL SYSTEMS
Hard-wired Systems Programmable Systems
Relays Microprocessors
Electronic Logic Computers
Pneumatic Logic PLC Systems
Hydraulic Logic
WHAT IS A PLC?
WHAT IS A PROGRAMMABLE
LOGIC CONTROLLER?
A Programmable Logic Controller is a

microprocessor based system which uses a
programmable memory for implementing specific
functions such as logic, sequencing, timing,
counting, & arithmetic to control through analog
or digital input modules, various types of
machines or processes.
PLC CONTROL PANEL
BACKGROUND
PLCs are used mainly in the motor industry in
1970s
 replaced large relay panels
 takes up lesser space
 more reliable in operation
 very flexible in control changes
PLC BACKGROUND
INITIAL SPECIFICATIONS
The controller must be:
 easily programmed and reprogrammed
 easily maintained and repaired
 more reliable in plant environment

 smaller than its relay equivalent
 cost competitive
COMPARISON BETWEEN PLC & COMPUTER
PLC FEATURES:
 low cost
 simple to program and install
 modular form
 error-checking capability
 suit industrial environment
COMPARISON BETWEEN PLC & RELAY
PLC FEATURES:
 fast operating speed
 easy installation
 very compact
 flexible in control changes

 more reliable
 simple maintenance
DISTRIBUTION OF FAULTS IN A
PLC SYSTEM
PLC SYSTEM
Programming
Device
Program
Memory
Input Input Processor Output Output

Devices Cards Cards Devices
PLC SYSTEM
The hardware (I/O connections) is independent

of the software (program).
The input devices are directly connected to the
input ports of the PLC and the output elements
are directly connected to the output ports of the
PLC.
There is no direct link between input and output
connections.
PLC HARDWARE DESIGN
PLCs are similar to computers which also consists

to three functional areas: processing, memory,
and input/output. Input signals to the PLC are
read and then stored in the memory, where the
processor performs the programmed logic
instructions on these input signals. Output signals
are then generated to drive output devices. The
action taken depends totally on the program
which is stored in the memory. In addition, a
programming unit is used to download the
program (software) to the PLC memory.
CENTRAL PROCESSING UNIT (CPU)
The CPU controls, monitors, and supervises all
operations within the PLC. It also carries out
programmed instructions stored in the memory. An
internal communications highway also known as bus
system, carries information to and from the CPU,
memory, and I/O units, under the control of the CPU.
FUNCTIONS OF THE CPU

 Reads the input signals from process
 Carries out programmed instructions stored in
the memory
 Produces output signals to drive actuators
INPUT/OUTPUT (I/O) UNITS
The I/O units form the interface between the

internal microelectronics of the PLC and the
outside world. It must therefore provide all the
necessary signal conditioning and isolation
functions. This often allows the PLC to be directly
connected to process sensors and actuators (e.g.
proximity switches & solenoids) without the need
for intermediate circuitry or relays.
INPUT/OUTPUT DEVICES
COMMONLY USED I/O DEVICES:
Input:
 switches
 limit switches
 reed switches
 proximity sensors, etc.
Output:
 lamps
 buzzers
 solenoids
 motors, etc.
SEMICONDUCTOR MEMORY
Volatile Memory Non-Volatile Memory
Non-Erasable Erasable
Memory Memory
RAM ROM PROM EPROM EEPROM
SEMICONDUCTOR MEMORIES
VOLATILE - those which loses their contents when
the power is switched off
RAM or Random Access Memory is the name given
to read/write memory, which allows individual
signals or data words to be written in or read out
when correct control signals are present.
Every word location can be written to, read, or
erased as often as required using RAM, but
because it is volatile, the entire contents will be
lost if the power is switched off. A back-up battery
must be fitted to the RAM if it is required to retain
its stored data.
NON-VOLATILE - when power is removed, this group
does not lose its data. This group
can be subdivided in erasable and
non-erasable memories.
Non-erasable Memories:
ROM or Read Only Memory which is permanently
programmed at manufacture and can not be
altered. ROMs are used when large batches of
identically programmed devices are to be
produced.
PROMs or Programmable ROMs can be programmed
by the user using a PROM programmer
Erasable Memories:
EPROM or Erasable PROMs are programmed in similar
way as PROMs. Their contents can be erased by
exposure to ultraviolet light for approximately 30
minutes. EPROMs can then be re-programmed,
over and over again.
EEPROM or Electrically Erasable PROMs are similar to

EPROMs but can be erased electrically while
connected in the circuit. After a program is fully
developed and tested, it can be downloaded
into a PROM or EPROM memory chip.
PROGRAMMING UNITS
1. Programming Console
2. Graphic Programmer
3. Personal computer
PROGRAMMING CONSOLE
GRAPHIC PROGRAMMING
CONSOLE
COMPUTER
PLC SELECTION
1. Input/Output Capacity
2. Types of I/O Required
3. Memory Size
4. Types of Software Languages
5. Future Expansion of the System
6. Support and Back-up
PERIPHERAL DEVICES
1. Programming console
2. Cassette Recorder
3. PROM Writer
4. Computer
5. Printer
6. Graphic Programming Console
PROGRAM DOCUMENTATION
1. Storing the programs in EPROMs

2. Storing the programs in floppy disks
3. Storing the programs in personal
computer
4. Printing the PLC programs using printer
RECOMMENDED STEPS TO BE TAKEN
FOR A PLC CONTROL SYSTEM
1. System design
2. Input/Output assignment
3. Writing the program
4. Programming
5. Editing
6. Monitoring
7. Program storage
REVIEW EXERCISES
Convert the following ladder diagrams to its equivalent
mnemonic codes:
1.
0000 0001 0005 0006 0501
0002 0003
0004
2.
0000 0001 0502
0002 0003 0004
0005
0502
3.
0000 0001 0005 0006 0503
0002 0003
0007
0004
4.
0000 00100
0001 00101
0002 00102
0003 00103
EXAMPLES
In a company, an electric bell is used as a signal to tell the
staff that it is time to start to work, go for teabreak, go for
lunch, and go home. A switch is used to activate the bell.
The bell rings when the switch is pressed. It will go off when
the switch is released.
Bell
Switch
A siren will sound when a switch is pressed. It will sound
continuously even when the activating force is removed. It
will go off when the switch is reset.
Siren
Switch
In a chemical plant, an indicating lamp will be lighted when
the pressure and the temperature rise above a certain level.
These two conditions are simulated by push button switches
Pb1 and Pb2. In other words, when both Pb1 and Pb2 are
pressed, the lamp will be lighted. When either one of them is
released, the lamp will go off.
Lamp
Pb1 Pb2
In a production line, an indicating lamp will be lighted
whenever an operator presses a pushbutton. This is to
capture the attention of the line leader whenever they
encounter a problem. Here, three stations are simulated
using pushbutton switches Pb1, Pb2, and Pb3 respectively.
Lamp
Pb1 Pb2 Pb3
Three sensors S1, S2, & S3 are used to detect short, medium, &
long workpieces on a conveyor system. A red, green, & blue
indicating lamp will be lighted if a short, medium, & long workpiece
is detected respectively. In other words, if S3 & not S1 & not S2 is
triggered, a short workpiece is detected, therefore a red indicating
lamp will be lighted. If S2 & S3 & not S1 are triggered, a medium
workpiece is detected, therefore a green indicating lamp will be
lighted. If S1 & S2 & S3 are triggered, a long workpiece is detected
therefore a blue indicating lamp will be lighted.
In a printing firm, a cutter is used to cut the side edges of the
papers. This cutter is controlled by a pneumatic cylinder. For the
safety of the operator, the cutter will move down only when both
pusbutton switches Pb1 & Pb2 are pressed and also a safety cover
is closed. This safety cover is closed manually and a limit switch is
used to detect the closed position. When one of the pushbuttons is
released or when the safety cover is opened, the cutter will
immediately return to its top position. The cylinder is controlled by
a single solenoid spring returned valve.
A huge steel door is installed in a deep mining tunnel. This door
may be opened or closed by two sets of pushbutton switches. One
set from inside and the other set from outside. The sliding unit is
controlled by a double solenoid valve.
Try solving this using:
a. Direct control
b. Indirect control
The opening and closing of a door (similar to a bus door) is
activated by using two pushbutton switches Pb1 and Pb2. Pb1 is for
opening and Pb2 is for closing the door.
The cylinder is controlled by:
a. A double solenoid valve
b. A single solenoid valve
By pressing a pushbutton (with the cylinder initially retracted),
a workpiece is pushed away from a gravity feed magazine onto
a conveyor system. The cylinder returns automatically when it
has reached the fully extended position. Fully retracted and
extended positions are sensed by reed switches RS1 and RS2.
The cylinder is controlled by a single solenoid spring return
valve.
When sensor S1 senses a container,
a pneumatic operated valve will open
and allows liquid from the tank to
flow into it. The valve closes
automatically after a time delay of 5
secs. After which the container will
be transported to another station.
For safety reasons, the valve closes
immediately when the container is
removed before the time delay
elapsed. Time delay starts when
sensor S1 is trigerred. The valve is
controlled by a rotary actuator which
is activated by a single solenoid
spring return valve.
Plastic components are to be joined together by the application
of adhesive, heat and pressure. Operation starts when a
pushbutton is activated. On reaching the forward end position,
the components are to be pressed together for 10 seconds.
After which the piston rod will return automatically to its
starting position
A working life cycle test is to be carried out on a double acting
cylinder. When a start-button switch is pressed, this cylinder will
extend and retract continuously. When 10000 cycles is reached, the
whole operation stops. It can only be restarted if a reset button
switch is activated. One cycle refers to the extension and retraction
of the cylinder. The extended and retracted positions are sensed by
reed switches Rs1 and Rs2. A stop button switch can be used to
stop the operation before the 10000 cycles are up. An interrupted
operation can be restarted by pressing the start button again.
Boxes arrive on a roller conveyor and transported onto the
second roller conveyor by cylinders A and B. Cylinder B must
not return until cylinder A has reached the retracted
position. The sequence will begin when sensor S1 detects a
workpiece. Each cylinder is controlled by a single solenoid
spring returned valve.
Parts are manually placed in a receptacle. A pneumatic cylinder
A pushes the receptacle under the drilling operation. The drill
feed unit is controlled by a pneumatic-hydraulic actuator B.
After drilling, cylinder A must not return until the drill feed unit
has reached its start position. The sequence will begin when a
start button is pressed. Each cylinder is controlled by a single
solenoid valve.

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Factory Automation

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Presents……...

It is mainly used to do work by being allowed to

Air is used to actuate instruments or controls which

Air quality is critical in the proper functioning of

- Compressed air is not cheap to produce

Compressor Aftercooler Air Tank

Piping Air Dryer Main Line

Air Service Working

DIAPHRAGM PISTON SCREW VANE

It is generally used in systems requiring

Air taken in at atmospheric pressure is

WATER COOLED AFTERCOOLER

An air receiver is a pressure vessel of welded

- to store sufficient compressed air to meet

- to minimize frequent “loading” and “unloading”

When atmospheric air cools, it will reach a

Compressed air can be fed from two sides to a point of

Water is driven in any direction and sufficient water

The pressure at the last few points are weaker due to

This lay-out is used where few take-off points are

A sub-micro filter will remove virtually all oil and

Manufacturers provide flow/pressure diagrams

It should be noted that using a standard filter

Pressure regulators may

DIRECTIONAL CONTROL VALVES

POPPET VALVES SLIDING VALVES

SPOOL PLANE SLIDE ROTARY

where: Flow path

METHOD OF OPERATION (left side)

PORTS DESIGNATION (based on ISO)

ISO 1219 ISO 5599

Spring returned valves are monostable. They have

LIMITED ANGLE OF ROTATION

A check valve allows free air flow in one

This component permits a maximum

SIGNAL INPUT LEVEL

ELECTRO-PNEUMATIC SYSTEMS ARE

0.3 mA SENSITIVITY EFFECT

 Allowable current/voltage that can be

The sensing distance depends on:

 Type and material of the sensing object

 Sensing head size of the sensor

The correct polarity of the applied

Inverse Polarity Protection Circuitry protects

Capacitive proximity sensors senses almost all

 Wide range of operating voltages

 Contact protection circuit required

 Contacts are affected by dirt and dust

Lines crossing Lines connection

- Slow-operating relay (energizing delay)

A Programmable Logic Controller is a

 very flexible in control changes

 more reliable in plant environment

 flexible in control changes

Input Input Processor Output Output

The hardware (I/O connections) is independent

PLCs are similar to computers which also consists

FUNCTIONS OF THE CPU

The I/O units form the interface between the

Volatile Memory Non-Volatile Memory

RAM ROM PROM EPROM EEPROM

EEPROM or Electrically Erasable PROMs are similar to

1. Storing the programs in EPROMs