Pneumatics

PNEUMA : means breath in Greek . Pneumatics is the name given to the branch of physics which deals with the properties, motions and behavior of air Pneumatics is a branch of technology, which deals with the study and application of use of pressurized gas to affect mechanical motion. Pneumatic systems are extensively used in industry, where factories are commonly plumbed with compressed air or other compressed inert gases. This is because a centrally-located and electrically-powered compressor that powers cylinders and other pneumatic devices through solenoid valves is often able to provide motive power in a cheaper, safer, more flexible, and more reliable way than a large number of electric motors and actuators. Pneumatics also has applications in dentistry, construction, mining, and other areas. Advantages of pneumatic

Simplicity of Design And Control o Machines are easily designed using standard cylinders & other components. Control is as easy as it is simple ON - OFF type control. Reliability o Pneumatic systems tend to have long operating lives and require very little maintenance. o Because gas is compressible, the equipment is less likely to be damaged by shock. The gas in pneumatics absorbs excessive force, whereas the fluid of hydraulics directly transfers force. Storage o Compressed Gas can be stored, allowing the use of machines when electrical power is lost. Safety o Very low chance of fire (compared to hydraulic oil). o Machines can be designed to be overload safe.

( en.wikipedia.org/wiki/Pneumatics)

Compressed Air as a Working Medium

Advantages: Air is available everywhere Compressed air is easily conveyed in pipelines over large distances Compressed air need not be returned Compressed air is insensitive to temperature fluctuations Compressed air is explosion proof Compressed air is clean Compressed air is fast

Disadvantages: Straight line movement can be produced directly. Compressed air is a relatively expensive means of conveying energy Compressed air requires good conditioning It is only economical up to a certain force expenditure. Air is compressible. Exhaust air is loud (reduced by using silencers). The oil mist mixed with air for lubricating purposes exhaust or escapes to the atmosphere

Air Preparation The aim of proper compressed air preparation is to remove contamination & moisture.The air generated from compressor should route through various filters & dryers to attain required quality class FILTERS: Pre-filters Service units (FRC) Fine & micro filters Carbon filters

DRYERS:

Refrigeration type Adsorption type Membrane type

Requirement of Air Preparation Water Separation. Water causes corrosion. Washes away lubrication. Filtration. Dust is responsible for abrasion. Reduces the effectiveness of lubricants. Pressure Regulation. Constant pressure is required for uniform performance of pneumatic components. Lubrication. Lubrication is required to replace lubricant lost due to effects of dust and water over prolonged periods. Reduces internal friction in components. Service Unit - Includes Filter Pressure Regulator Lubricator

Port Numbering and Lettering System Number 1 3, 5 2, 4 10 12 14 Letter P Reserved for Pressure Source.

(R)S, R Reserved for exhaust ports. (A)B, A Reserved for working ports. Y Y, Z Z Port 1 closed. Port 1 connects to port 2. Port 1 connects to port 4.

As a general rule Odd numbers are at the bottom and Even numbers on the top Actuators

An actuator is an output device for the conversion of supply energy into useful work. They can be described Into two groups. Linear Motion Single Acting Cylinders Double Acting Cylinders

Rotary Motion Air Motor Rotary Actuator

Fig. Single acting cylinder

Fig. Double acting cylinder

Actuators Operation An Actuator Can be Controlled by the Following Methods: Pneumatic Hydraulic Electrical

Linear motion Single Acting Cylinders Double Acting Cylinders

Different Types of Valves: 3/2 Normally Closed:

It is push button operated and spring returned & normally closed. 3/2 Normally Open:

It has three ports & two position. It is normally opened and spring returned with push button.

5/2 Normally Open

It has five ports, two position, spring returned and normally opened with push button. 5/2 Normally closed

It has five ports, two position and normally opened valve. It is spring returned with push button. Roller with idle return

It has three ports, two control positions, spring returned with roller. Non Return Valve (The Shuttle Valve)

Check valve Spring loaded check valve Shuttle valve: or function

Input to X OR Y gives output at A . Also referred to as the OR valve and sometimes represented by the symbol.

Non Return Valve Two pressure valve AND function Quick exhaust valve

Also referred to as the AND valve and sometimes represented by the above symbol Flow Control valve

Flow control valve adjustable One-way flow control valve

Basic Principles of Flow Control Some important points about flow control The speed of a cylinder depends upon the rate of flow of air entering or leaving the cylinder. Slowing down the rate of flow of air entering or leaving a cylinder, slows down cylinder speed. Air that is entering the cylinder is known as Supply air, or Inlet air. Air that is leaving a cylinder is known as Exhaust air.

The Shuttle Valve Input to X OR Y gives output at A

Also referred to as the OR valve and sometimes represented by the symbol

The 2 Pressure Valve Input to X AND Y gives output at A

Also referred to as the AND valve and sometimes represented by the symbol

Pilot valve A pilot valve is a small valve that controls a limited-flow control feed to a separate piloted valve. Typically, this valve controls a high pressure or high flow feed. Pilot valves are useful because they allow a small and easily operated feed to control a much higher pressure or higher flow feed, which would otherwise require a much larger force to operate; indeed, this is even useful when a solenoid is used to operate the valve. Pilot valves are often used in critical applications (i.e., emergency and safety controls) and are human-operated. They can be set up as a push-to-activate or dead man's switch. It works like a trigger. When valve is triggered one portion is overlapped by piloted portion.

Fig. Single pilot with spring return. Time Delayed Start of Cylinder

Fig. Double Pilot valve.

In industrial purposes it is needed to make a lot which contains some definite number of products. For solving such problems delay valve is used.

Project

Here there is a project. Main objective of this project is to move object from one position to another. Forward position of cylinder A is( A+), backward movement is (A-) and Forward movement of Cylinder B is (B+) & Backward movement is (B-) Solution There are two solutions. 1) A+B+A-B2) A+B+B-A-

Pneumatic Solution

Fig. Continuous flow (A+B+A-B-)

Fig. A+B+B-A-

Electro-Pneumatic The electro-pneumatic action is a control system for pipe organs, whereby air pressure, controlled by an electric current and operated by the keys of an organ console, opens and closes

valves within wind chests, allowing the pipes to speak. This system also allows the console to be physically detached from the organ itself. The only connection was via an electrical cable from the console to the relay, with some early organ consoles utilizing a separate wind supply to operate combination pistons. Advantages: An electro-pneumatic action requires less current or amperage to operate than a direct electric action. This causes less demand on switch contacts. An organ using electro-pneumatic action was more reliable in operation than early direct electric organs until improvements were made in direct electric components Why we choose Electro-pneumatic: High speed Intensive and Mature Technology Easily available, low on cost Reliability Long service life Offers a much wider range of products and applications The advent of PLCs have meant that jobs which were unachievable before can be performed

General Application of Electro-pneumatics Clamping Shifting Orienting Positioning Diverting Feeding

Electro-Pneumatic Components

Switches and contacts

Normally open switch Normally open switch is one in which flow of electricity is not happened. But when switch is on then causes of electricity.

Normally closed switch Normally closed switch is one in which flow of electricity is normally happened. But when switch is on then causes fall of electricity.

Relays A Relay has Certain Characteristics Low Maintenance Able to Switch a Number of Independent Circuit Paths Easily Adaptable to Various Operating Voltages High Operating Speed, ie. Short Switching Times Can be Used as a Logic or Interlocking Device

Relays, timers and solenoids

Basic logic functions

There are four commonly used logic functions in Electro-Pneumatics. YES Function NOT Function OR Function AND Function

Basic electrical circuits

+4 2V +4 2V +4 2V +4 2V

P s B tto uh u n

P shB tto u u n

Lm ap
0 V 0 V 0 V

Lm a p

0 V

Fig. YES Function

+4 2V +4 2V S 1 S 2

Fig. NOT Function

+4 2V +4 2V S 1

S 2

Lm ap
0 V 0 V
0 V

Lm ap

0 V

Fig.OR Function Limit Switches

Fig.AND Function

Limit switches are considered to be contact sensors, as it needs to be actuated to give a signal output.

Fig. Limit Switches Solenoid valves The directional control valves used in electro pneumatics are similar to those used in pure pneumatics. The only difference is that they are actuated by solenoids.

Pilot signal flow

Some Projects

Fig. A+B+B-A-

Digital Technique

Fig.A+B+A-B-