INTRODUCTION

TO
PNEUMATICS
 PNEUMATICS
• Technology of Pneumatics deals with the study of the behavior and
application of compressed air
• Science of air is known to man for centuries
• Not used in industry before the beginning of the Second World war
(1939-44)
• Many industries all over the developed western countries started
switching over to more & more automatic equipment and machineries
• Origin of Pneumatics – Manufacturing & other activities to meet the
sudden need of enhanced production of war commodities under the
tremendous shortage of skilled manpower (concept of automation)
• Cheaper medium of Industrial automation
• Maximum application of pneumatics – Construction (power hammers,
drills, riveting hammers, pneumatic cranes, air brakes, printing presses
etc.)
 PNEUMATICS – Notable Features
• Wide availability of air

• Compressibility of air

• Easy transportability

• Explosion proof characteristics of the medium

• Simple construction of pneumatic elements and easy handling

• High degree of controllability of pressure, speed and force

• Possibility of easy but reasonably reliable remote controlling

• Easier maintenance

• Comparatively cheaper in cost than other systems

 PNEUMATICS – Physical Principles
• Earth is surrounded by air up to a height of approximately 1600 km
above the top surface of the earth

• Gaseous layer of air around the earth is known as atmosphere

• Main constituents of air by volume –

- Nitrogen : 78%
- Oxygen : 21 %
- Carbon dioxide & other gases : 1%

• Air which is a mixture of various chemical elements follows the gas

laws.
GAS LAWS
GAS LAWS
 PNEUMATICS REVIEW
• Played an important role as a Technology in the performance of
Mechanical Work
• In the majority of applications compressed Air is used for one or more
of the following functions
- To determine status of the processor (sensor)
- Information processing (processors)
- Switching of actuators by means of final control elements
- Carrying out work (actuators)
• Interaction of all the above governs installation and control of
machinery
PNEUMATICS REVIEW
PNEUMATICS REVIEW
APPLICATIONS
APPLICATIONS
APPLICATIONS

Pneumatic Bending device

USAGE OF PNEUMATICS
ADVANTAGES & CHARACTERISTICS
OF COMPRESSED AIR
DISADVANTAGES OF PNEUMATICS
GENERAL FACTORS FOR COMPARING
OTHER FORMS OF ENERGY
CRITERIA FOR WORKING MEDIA

• Power requirements
• Temperature variations
CRITERIA FOR CONTROL MEDIA
PNEUMATICS & CONTROL
SYSTEM DEVELOPMENT
STRUCTURE & SIGNAL FLOW OF
PNEUMATIC SYSTEMS
STRUCTURE & SIGNAL FLOW OF
PNEUMATIC SYSTEMS
PNEUMATIC CONTROL SYSTEM
BREAKDOWN OF CONTROL CHAIN
CIRCUIT DIAGRAM & PNEUMATIC ELE.
 BASIC REQUIREMENTS FOR
INTRODUCING PNEUMATICS IN A PLANT
1. Compressor plant

2. Pipeline

3. Control valves

4. Air actuator

5. Auxiliary appliances
COMPONENTS – PNEUMATIC SYSTEM
COMPARISION
COMPARISION
COMPARISION
COMPARISION
PNEUMATIC
ACTUATORS
 PNEUMATIC ACTUATORS
• Similar to Hydraulic actuators
• Converts air pressure into linear or rotary motion
• Used for variety of applications such as Gripping, Pulling or pushing
of objects
CLSSIFICATION
• Linear actuators ( air cylinders)
- Single acting
- Double acting (Normal, Double rod, Turn cylinder, Tandem
cylinder, Multi-position cylinder)
- Ram cylinders - Single rod
- Rod-less cylinders - Diaphragm cylinders
- Rolling diaphragm cylinder
• Rotary actuators ( air motors)
- Vane type Semi-rotary actuator
- Rack & pinion type actuator
- Rotary cylinder type actuator
SINGLE ACTING CYLINDER
SINGLE ACTING CYLINDER
PNEUMATIC ACTUATORS
PNEUMATIC ACTUATORS
PNEUMATIC ACTUATORS
PNEUMATIC ACTUATORS
PNEUMATIC ACTUATORS
PNEUMATIC ACTUATORS

DOUBLR ROD NON-ROTATING CYLINDER

PNEUMATIC ACTUATORS

ROTARY CYLINDER
 ROD-LESS CYLINDERS
• Three different operational principles used for construction of rodless
cylinders are
- Sealing band cylinder
- Band or cable cylinder
- Cylinder with magnetic coupling

SEALING BAND CYLINDER

ROD-LESS CYLINDERS

BAND or CABLE CYLINDER

ROD-LESS CYLINDERS

CYLINDER WITH MAGNETIC COUPLING

ROTARY CYLINDER TYPE ACTUATOR
 DESIGN PARAMETER - SELECTION

1. Size

2. Speed

3. Environmental protection

4. Maintenance

5. Direction reversal
 Previously Discussed Bits…..
• End position cushioning

• Seals

• Mounting arrangements
DIRECTIONAL
CONTROL
VALVES
 PNEUMATIC CONTROLS
PURPOSE OF VALVE
• For controlling the to and fro motion of a pneumatic cylinder, the air
energy has to be regulated, controlled and reversed with a
predetermined sequence in a pneumatic system
• Control of pressure and flow
VALVE DEFINATION
• Fluid power elements used for controlling and regulating the
working medium
VALVE USAGE
• To start & stop pneumatic energy
• Control the direction of flow of compressed air
• Control the flow rate of the compressed air
• Control the pressure rating of the compressed air
VALVE TYPES
1. DCV 2. Non-return valves 3. FCV 4. PCV
 DIRECTION CONTROL VALVES
• Used mainly to direct the flow of the pressure fluid in the desired
direction
• Main function – To start, stop and regulate the direction of air flow
and help distribution of air in the desired line
• DCV’s has generally 2, 3, 4, or 5 ports / openings / ways
• Ways are designated by letters or alphabets such as :
P = Compressor line port
R = Exhaust port
A&B = working ports to cylinders or motors
• DCV’s are basically classified as
- Seat or poppet valves
- Spool or sliding valves
SEAT Vs SPOOL VALVES
SEAT / POPPET
TYPE VALVES
3/2 SEAT TYPE VALVE
4/2 SEAT TYPE
SPOOL / SLIDING
TYPE VALVES
2/2 SPOOL VALVE
3/2 SPOOL VALVE
4/2 SPOOL VALVE
5/2 DCV
5/2 PILOT OPERATED DCV
5/3 WAY VALVE
SUSPENDED SEAT TYPE VALVE
CONTROL
ACTUATION
OF VALVES
 SPEED
REGULATORS
FIXED TYPE FCV
NON-RETURN TYPE FCV
CHECK VALVE
TWIN PRESSURE VALVE
TWIN PRESSURE VALVE - USAGE
SOLENOID OPERATED
VALVE (3 WAY)
 SIMPLE
PNEUMATIC
CONTROL
ISO SYMBOLS FOR FLUID CIRCUITS
ELECTRICAL SYMBOLS
USED IN
PNEUMATIC CIRCUITS
PNEUMATIC CIRCUITS
DIRECT CONTROL
DIRECT ACTUATION
INDIRECT ACTUATION
PILOT CONTROL OF A SINGLE ACTING CYL.
PILOT CONTROL OF A DOUBLE ACTING CYL.
SPEED CONTROL – SINGLE ACTING CYL.
SPEED CONTROL – DOUBLE ACTING CYL.
AIR PILOT CONTROL – DOUBLE ACTING CYL.
SEMI AUTOMATIC CONTROL – DOUBLE ACTING
TWO STEP SPEED CONTROL OF A CYLINDER
ACTUATION OF A PNEUMATIC MOTOR
AUTOMATIC TO & FRO MOTION OF A
DOUBLE ACTING CYLINDER
SEQUENCING CIRCUIT
MEMORY VALVE
FLOW CONTROL VALVE
FLOW CONTROL VALVE
FLOW CONTROL VALVE
SUPPLY AIR THROTLLING
EXHAUST AIR THROTLLING
QUICK EXHAUST VALVE
QUICK EXHAUST VALVE
QUICK EXHAUST VALVE
QUICK EXHAUST VALVE
 SIGNAL
PROCESSING
ELEMENTS
 SYNOPSIS
• Non-moving logic elements find a prominent place in Finer Control
Engineering

• Characteristics offered by fluidic elements proves them to be at par

with electronic controls

• Development of various fluidic elements conforms the need of logic

functions in Industrial Automation

• Tesla’s fluid-diode & Theory of “Wall-attachment” – Canada forms

the basic principle

• Better control & feedback to the Pneumatic systems – Use Logic

Gates along with power pneumatic circuits

• Major area of application – Field of Sensors

 FLUIDICS
• Susceptibility to wear & tear of mechanical parts – Major problem in
Hydraulics and Pneumatics
• Challenge – Development of reliable control system without turning
towards Electronics
• Specific need of control engineering forced engineers for a solution
within the fluid power system – Development of new types of fluid
power elements in early 60’s – FLUIDIC ELEMENTS or FLUID
LOGIC ELEMENTS
• Biggest advantage – Minimum number of mechanical moving parts
(no wear & tear) – NON-MOVING LOGIC CONTROLLERS
• Much more reliable under adverse environmental conditions
(vibration, shock, heat, radiation, electromagnetic interference etc.)
• Simpler in construction, Smaller in size, Mode of energy feeding is
very simple, Very little space to mount
• Mostly employ working medium as AIR
• Easily adoptable to Logic Functions
 FLUIDICS
It is the study of the performance and
response characteristics of control
systems, computing devices and logical
switchgears based on fluidic elements
OR
The subject which deals with the area of
fluid logics is called fluidics
 HISTORICAL BACKGROUND

• Tesla invented a conduit in 1916 for fluids

• Easy & Difficult floe direction owing to the interference caused by the
divided branch flow opposing the intended flow direction
• Strong influence of electronics in this era accounts for the terminology
“fluid-diode” used to describe Tesla’s valved conduit
• Real Development – CONANDA EFFECT – Named after Henri
Conanda – Observed and reported WALL-ATTACHMENT
phenomenon
 HISTORICAL BACKGROUND

• WALL-ATTACHMENT
When a jet of fluid is pushed into an inclined wall, it will stay there,
even after the pushing control jet is removed (1933)
He noted that entrainment of the trapped air next to the surface of the
body over which it is moving creates a partial vacuum and the
atmospheric air forces the fluid stream to cling to the surface of the
solid over which the fluid is to travel

• Existence of fluidic devices – 60’s - termed as fluid amplifier

• Working pressure used for pneumatic fluidic devices is very less –

within 0 to 0.05 to 0.1 bar
WHAT MAKES IT WORK?
BI-STABLE FLIP-FLOP
 PNEUMATIC SIGNAL PROCESSING
• Involves use of Pneumatic Logic Elements
• Uses of air valves & other devices for control actions
• Application of control actions to power systems to obtain the required
actuation
• Conversion of minimum force to signals to operate high pressure
control valves

LOGICS IN PNEUMATIC CIRCUIT DESIGN

• Logic Controls – Design of control system based on reasoning arising
out of deductive principle

• Famous Greek philosopher ARISTOTLE (384 – 322 BC) – Father of

deductive logic
 LOGIC FUNCTIONS

• Pneumatic Shuttle valve and Dual pressure valve

have logic functions

• Both have two inputs and two outputs each

• Shuttle valve characteristic – OR function

• Dual pressure valve characteristic – AND function

COMMON LOGIC FUNCTIONS

Memory
COMMON LOGIC FUNCTIONS
COMMON LOGIC FUNCTIONS

Time Dependent Limited Memory

COMMON LOGIC FUNCTIONS

AND Function
LOGIC FUNCTIONS & BOOLEAN ALGEBRA
 LOGIC AND FUNCTION
Logic Symbol Truth Table

Logic Equation
 LOGIC AND FUNCTION

Pneumatic Symbol

PROBLEM - 1
 LOGIC
AND
FUNCTION
SOLUTION
ALTERNATIVE
SOLUTION
PROBLEM - 2
POSITIONAL
SKETCH
 LOGIC OR FUNCTION

Logic Symbol Truth Table

Logic Equation
LOGIC OR FUNCTION

Pneumatic Symbol
 LOGIC OR FUNCTION
PROBLEM - 3

SOLUTION
 LOGIC OR FUNCTION
PROBLEM - 4

SOLUTION
PROBLEM - 5
POSITIONAL SKETCH
 PRESSURE DEPENDENT CONTROL
PROBLEM - 6

SOLUTION
POSITIONAL
SKETCH
PRESSURE DEPENDENT CONTROL
 PRESSURE DEPENDENT CONTROL –
EMBOSSING OF PLASTIC COMPONENTS
PROBLEM - 7
POSITIONAL
SKETCH
 TIME DEPENDENT CONTROL
• In certain applications, the cylinder may have to be
retained in its extended position for a particular time

• Automated Adhesive bonding operation

• Usage of TIME DELAY VALVE

TIME DELAY VALVE
TIME DELAY VALVE - Symbol
 TIME DELAY VALVE
PROBLEM - 8

SOLUTION
POSITIONAL SKETCH
PROBLEM - 9
POSITIONAL SKETCH
 MULTI-
CYLINDER
APPLICATIONS
INTRODUCTION
MOVEMENT DIAGRAM
TRAVEL TIME DIAGRAM
 POSITION STEP DIAGRAM /
MOTION CONTROL DIAGRAM
POSITION STEP DIAGRAM OF A PNEUMATIC
CIRCUIT WITH TWO CYLINDERS
PNEUMATIC CIRCUIT AS PER
POSITION STEP DIAGRAM
POSITIONAL
SKETCH
DISPLACEMENT - STEP DIAGRAM
CIRCUIT DIAGRAM – INITIAL POSITION
SOLUTION Continued…..
SOLUTION Continued…..
REPRESENTATION OF STEP - 1
REPRESENTATION OF STEP - 2
REPRESENTATION OF STEP - 3
REPRESENTATION OF STEP - 4
REPRESENTATION OF STEP - 5
 CASCADE SYSTEM OF
PNEUMATIC CIRCUIT DESIGN

PRINCIPLE & PROCEDURE

PRINCIPLE & PROCEDURE Continued…..
FLOW LINES IN CASCADE SYSTEM

FIG. 10.6
PRINCIPLE & PROCEDURE Continued…..
POSITION STEP DIAGRAM FOR A 3
CYLINDER PNEUMATIC SYSTEM

FIG. 10.7
PRINCIPLE & PROCEDURE Continued…..
FIG. 10.8
 CO-ORDINATED MOTION
PROBLEM - 1

SOLUTION
SEQUENTIAL MOTION CONTROL

INEFFECTIVE WAY
 POSITION STEP DIAGRAM /
MOTION CONTROL DIAGRAM
LIMIT SWITCHES
EFFECTIVE WAY
 POSITION STEP DIAGRAM /
MOTION CONTROL DIAGRAM
 SIGNAL ELIMINATION BY
REVERSING VALVES

PROBLEM - 2
SOLUTION
SOLUTION Continued…..

PROBLEM - 3
POSITIONAL
SKETCH
DISPLACEMENT -
STEP DIAGRAM