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Nikini

ELECTROPNEUMATICS

Nikini Automation Systems (Pvt.) Ltd.

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

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Overview
1.
2.
3.
4.
5.
6.

Introduction to Electro-pneumatics systems


Switches and Sensors
Recognizing and drawing of electrical symbols
Electrical Signal processing
Electro-pneumatic actuators
Solving simple control problems using electropneumatics
7. Solving control problems using multi actuator
electro-pneumatic systems
Electropneumatics

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Tuesday, September 21, 2010

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Timing of the workshop

Electropneumatics

Session 1
Break
Session 2
Lunch
Session 3
Break
Session 4
Conclusion

09.00 a.m.
10.15 a.m.
10.30 a.m.
12.15 p.m.
01.15 p.m.
03.00 p.m.
03.15 p.m.
04.00 p.m.
Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

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1.Introduction
Electropneumatics is controlling of pneumatic
systems using electrical control systems.
Hybrid system using of both pneumatic and
electrical energies.
Used in many areas of industrial automation.
Production
Assembly and packaging systems
Etc.

Electropneumatics

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Tuesday, September 21, 2010

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Control Engineering
Pneumatic drives can only do work usefully if
their motions are precise and carried out at the
right time and in the right sequence.
Coordinating the sequence of motion is the task of
the controller.
Control engineering deals with the design and
structure of controllers.

Electropneumatics

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Tuesday, September 21, 2010

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Pneumatic control system pneumatic components are used.


Various types of valves
Sequencers
air barriers
Electro-pneumatic control system electrical components
are used.
electrical input buttons
proximity switches
relays
programmable logic controller
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Signal
Output

Signal
Processing

Final control element


Directional control
valves

Processing elements
Shuttle valves
Two-pressure valves
Pressure control valves
Sequences
Input elements

Signal Input

Signal Flow
Electropneumatics

Directional control valves


(Mechanically operated/
Manually operated)
Air barriers

Pneumatic control section

Command
execution

Power Components
Cylinder
Swivel cylinder
Pneumatic motor
Optical display

Pneumatic power
section

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Pneumatic components
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Tuesday, September 21, 2010

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Cylinder
Swivel cylinder
Pneumatic motor
Optical display

Final control element


Signal
Output

Electro pneumatically
operated directional
control valves

Processing elements
Signal
Processing

Relays
Contactors
Programmable logic
controllers (PLCs)

Input elements
Signal
Input

Signal Flow
Electropneumatics

Push buttons
Control switches
Limit switches
Reed switches
Sensors
Light barriers
Pressure switches

Electrical control section

Command
execution

Pneumatic power
section

Power Components

Electropneumatic
components
Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

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Electrical control section

Electrical directional control valve


Cylinder with proximity switches
Electropneumatics

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Tuesday, September 21, 2010

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Advantages of electro pneumatic


controllers
High reliability:
Fewer moving parts subject to wear

Lower planning and commissioning effort


For complex controls.

Lower installation effort


when modern components such as valve terminals are
used.

Simpler exchange of information between several


controllers.

Electropneumatics

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Tuesday, September 21, 2010

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Electro-pneumatic controllers have asserted


themselves in modern industrial practice.
Application of purely pneumatic controls systems
is limited to a fewer special applications.

Electropneumatics

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Tuesday, September 21, 2010

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Fundaments of electrical
technology

A simple electrical circuit consists of a


voltage source, a load, and connection lines.
Electrical current.
Current can only flow if the circuit is closed.

Two types of current


Direct current
Alternating current

Electropneumatics

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Tuesday, September 21, 2010

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Electropneumatics

Alternating current

Time (t)

Current

Current

Direct current

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Time (t)

Tuesday, September 21, 2010

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DC circuit

S
4

V=12V
H

Electropneumatics

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Tuesday, September 21, 2010

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Power supply unit

Electropneumatics

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Tuesday, September 21, 2010

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The transformer reduces the operating voltage.


230 V to 24 V
The rectifier converts the AC voltage into DC
voltage.
The capacitor at the rectifier output smoothes the
voltage.
The voltage regulator
To ensure that the electrical voltage remains
constant regardless of the current flowing.
Electropneumatics

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Tuesday, September 21, 2010

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2.Switches
Switches (& Sensors) are the means of
signal generation in a electrical control
system.
Switches are installed in circuits to apply a
current to a load or to interrupt the circuit.
Basic components of the switch are
contacts.
There are many ways to actuate a switch.
Electropneumatics

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Tuesday, September 21, 2010

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Normally open contact

Electropneumatics

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Tuesday, September 21, 2010

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Normally closed contact

Electropneumatics

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Changeover contact

Electropneumatics

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Tuesday, September 21, 2010

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Input elements Switches
Normally open push button

Electropneumatics

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Tuesday, September 21, 2010

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Input elements Switches
Normally closed push button

Electropneumatics

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Tuesday, September 21, 2010

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Input elements Switches
Change over switch

Electropneumatics

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Tuesday, September 21, 2010

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Input elements Switches
Please refer to the video to get a summarization
of the different kind of switches

Switches NO, NC, CO

and an application example !

Application of switches

Electropneumatics

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Tuesday, September 21, 2010

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Input elements Switches
Please check the numbers of the contacts of a
normally open and normally closed contact at the
signal input device of Festo.
Are there any differences and if yes which one?

Electropneumatics

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Tuesday, September 21, 2010

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Identity logic

Pushbutton (make)

Electrical connection 0V

Electropneumatics

Indicator light

Electrical connection 24V

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Tuesday, September 21, 2010

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Negation Logic

Pushbutton (make)

Electrical connection 0V

Electropneumatics

Pushbutton (break)

Indicator light

Electrical connection 24V

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Tuesday, September 21, 2010

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AND Logic

Pushbutton (make)

Electrical connection 0V

Electropneumatics

Pushbutton (make)

Indicator light

Electrical connection 24V

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Tuesday, September 21, 2010

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OR Function

Pushbutton (make)

Electrical connection 0V

Electropneumatics

Pushbutton (make)

Indicator light

Electrical connection 24V

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Tuesday, September 21, 2010

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Mechanical limit switch


1: Reset spring

L1

2: Housing
3: Swing lever
4: Guide pin
5: Leaf spring
6: Contact spring

Normally open
contact
Normally close
contact

Electropneumatics

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Tuesday, September 21, 2010

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Mechanical limit switch

Electropneumatics

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Tuesday, September 21, 2010

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Switching Contacts and Types of


Actuation: Symbols

Electropneumatics

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Tuesday, September 21, 2010

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4.Signal Processors: Relays

Electropneumatics

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Tuesday, September 21, 2010

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Relays
A relay is an electro magnetically actuated switch.
When a voltage is applied to the relay coil, an
electromagnet field results.
This causes the armature to be attracted to the coil
core.
The armature actuates the relay contacts, either
closing or opening them, depending on the design.
A return spring returns the armature to its initial
position when the current to the coil is interrupted.
Electropneumatics

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Tuesday, September 21, 2010

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Processing elements Relays Repetition
Symbol

Cover
12

Return spring

14

A1

22

24

Armature
Coil

A2

11

21

Contacts

Contact connections

Coil connections
Electropneumatics

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Tuesday, September 21, 2010

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Processing elements Relays Repetition

Symbol
12

14

A1

A2

A1
Electropneumatics

A2

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11

22

24

21

1
Tuesday, September 21, 2010

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Processing elements Relays Repetition

Symbol
12

14

A1

A2

A1
Electropneumatics

A2

Nikini Automation Systems (Pvt) Ltd

11

22

24

21

1
Tuesday, September 21, 2010

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Processing elements Relays Repetition

Symbol
12

14

A1

A2

A1
Electropneumatics

A2

Nikini Automation Systems (Pvt) Ltd

11

22

24

21

1
Tuesday, September 21, 2010

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Processing elements Relays Repetition

Symbol
12

14

A1

A2

A1
Electropneumatics

A2

Nikini Automation Systems (Pvt) Ltd

11

22

24

21

1
Tuesday, September 21, 2010

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Relay Contact Configuration

Electropneumatics

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Tuesday, September 21, 2010

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Charateristics of a Relay
A Relay has Certain Characteristics

Electropneumatics

Different voltage levels


Multiple switching operation
Different control paths
Used for logic functions and interlocking
Ease of maintenance

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Tuesday, September 21, 2010

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Exercise

The exercise should be:


is it possible to connect a
solenoid of a valve 1M1 directly
via a proximity sensor 1B1 if the
data are:
P of the valve = 4.5 W at 24 VDC
and
I max over the sensor = 50 mA
Internal resistor of the proximity
sensor is 0
ANSWER:______________
Electropneumatics

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Tuesday, September 21, 2010

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May be it could help to put
another resistor in front of the
solenoid to reduce the current.
The questions are here:

Solution 1

R1

Electropneumatics

1. What is the value of the


resistor R1?
2. What is the real power over the
solenoid and
is that enough to switch the
valve

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Tuesday, September 21, 2010

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Solution 2

The perfect solution is to connect


any kind of sensors and switches
to a relay first and the
corresponding relay contact to the
solenoid of the valve.

Electropneumatics

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Tuesday, September 21, 2010

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Contactors
Contactors operate in the same way as a
relay.
Typical features of a contactor are:
Double switching (dual contacts)
Closed chambers (arc quenching chambers)

These design features allow contactors to


switch much higher currents than relays.

Electropneumatics

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Tuesday, September 21, 2010

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Contactors

Electropneumatics

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Tuesday, September 21, 2010

Solenoids

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Function of a solenoid

In electropneumatic controls,
solenoids are primarily used to
control the switching of valves,
relays or contactors.

Electropneumatics

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Tuesday, September 21, 2010

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Function of a solenoid
A magnetic field is induced when
a current is passed through an
electrical conductor. The strength
of the magnetic field is
proportional to the current.
Magnetic fields attract iron,
nickel and cobalt. The attraction
increases with the strength of the
magnetic field.

Electropneumatics

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Tuesday, September 21, 2010

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Function of a solenoid

Please refer to the video to get some additional


information regarding the phenomena of
electromagnetism
Electromagnetis
m principles

Electropneumatics

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Tuesday, September 21, 2010

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2/2 Way solenoid valve


2/2-Way solenoid valve without pilot control

Electropneumatics

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Tuesday, September 21, 2010

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Direct/ Pilot solenoid valves


Disadvantages of direct solenoids:

Electropneumatics

Higher force required to actuate the armature.


Larger dimensions of the coil head.
Higher power consumption.
Heating.

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Tuesday, September 21, 2010

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Solenoid Valves with Pilot Control


Solenoid valves with pilot control consist of:
An electromagnetically-actuated pilot control valve.
A pneumatically-actuated main valve.

Advantages:

Electropneumatics

Lower force required to actuate the armature.


Smaller dimensions of the coil head.
Lower power consumption.
Less heat generated.

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Tuesday, September 21, 2010

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3/2 Way solenoid valve


3/2-Way Single solenoid valve with pilot control

Electropneumatics

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Tuesday, September 21, 2010

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Pilot operation

Electropneumatics

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Tuesday, September 21, 2010

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5/2 Way single solenoid valve


1M1

5/2-Way Single solenoid valve with pilot control


Electropneumatics

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Tuesday, September 21, 2010

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5/2 Way single solenoid valve


5/2-Way Single solenoid valve with pilot control and exhaust for pilot

Electropneumatics

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Tuesday, September 21, 2010

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Control elements Pilot controlled 5/2 way valve single solenoid

5
4
1
(A) (S) (P)
Electropneumatics

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2
3
(B) (R)
Tuesday, September 21, 2010

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Control elements Pilot controlled 5/2 way valve single solenoid

5
4
1
(A) (S) (P)
Electropneumatics

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2
3
(B) (R)
Tuesday, September 21, 2010

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Control elements Pilot controlled 5/2 way valve single solenoid

5
4
1
(A) (S) (P)
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

2
3
(B) (R)
Tuesday, September 21, 2010

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Control elements Pilot controlled 5/2 way valve single solenoid

5
4
1
(A) (S) (P)
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

2
3
(B) (R)
Tuesday, September 21, 2010

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Control elements Pilot controlled 5/2 way valve single solenoid

5
4
1
(A) (S) (P)
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

2
3
(B) (R)
Tuesday, September 21, 2010

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Control elements Pilot controlled 5/2 way valve single solenoid

5
4
1
(A) (S) (P)
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

2
3
(B) (R)
Tuesday, September 21, 2010

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Control elements Pilot controlled 5/2 way valve single solenoid

5
4
1
(A) (S) (P)
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

2
3
(B) (R)
Tuesday, September 21, 2010

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Control elements Pilot controlled 5/2 way valve single solenoid

5
4
1
(A) (S) (P)
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

2
3
(B) (R)
Tuesday, September 21, 2010

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GO WITH THE FLOW!

5 1 3

Electropneumatics

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Tuesday, September 21, 2010

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Control elements Solenoid valves
1M1

Electropneumatics

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1M2

Pilot controlled 5/2 way


valve double solenoid

Tuesday, September 21, 2010

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5/2 Way double solenoid valve


5/2-Way double solenoid valve with pilot control and exhaust for pilot

Electropneumatics

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Tuesday, September 21, 2010

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Control elements Solenoid valves Summarization

Summarization pilot controlled solenoid valves

Electropneumatics

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Tuesday, September 21, 2010

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5/3 Way solenoid valve

Electropneumatics

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Tuesday, September 21, 2010

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Common Solenoid Valves


Valve Type

Symbol

Applications

Pilot controlled spring


return 2/2-way valve

Shut-off function

Pilot controlled spring


return 3/2-way valve,
normally closed

Single-acting
cylinders

Pilot controlled spring


return 3/2-way
valve,normally open

Switching
compressed air
on and off

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

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Common Solenoid Valves


Valve Type

Symbol

Applications

Pilot controlled spring


return 4/2-way valve

Double-acting linear or
swivel cylinders

Pilot controlled
springreturn 5/2-way
valve

Double-acting linear or
swivel cylinders

Electropneumatics

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Tuesday, September 21, 2010

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Common Solenoid Valves


Valve Type

Symbol

Pilot controlled
springreturn 5/2-way valve
(normally closed,
exhausted or
pressurized)Pilot
controlled spring return
4/2-way valve

Electropneumatics

Applications
Double-acting linear or
swivel cylinders with
intermediate stop, with
special requirements
regarding behavior in
event of power failure.

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

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Common Solenoid Valves


Valve Type

Symbol

Applications

Pilot controlled 4/2way double solenoid


valve

Double-acting linear or
swivel cylinder

Pilot controlled 5/2way double solenoid


valve

Double-acting linear or
swivel cylinder

Electropneumatics

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Tuesday, September 21, 2010

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Switching Symbols for Solenoid


Coils and Relays

Electropneumatics

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Electrical Output Devices

Electropneumatics

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Electropneumatic Exercises

Electropneumatics

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Tuesday, September 21, 2010

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Circuit Diagram Conventions

Pneumatic Circuit
Electropneumatics

Electrical Circuit
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Tuesday, September 21, 2010

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Circuit Diagram Structure


Pneumatic Circuit Diagram
The arrangement of the components follows the signal
flow accordingly from bottom to top.
Cylinders and valves are drawn horizontally.
The outward travel motion of cylinders should be from
left to right.

Electrical
The arrangement of the components follows the signal
flow accordingly from top to bottom.
The electrical circuit diagram can be subdivided into a
control part and a power part.
Electropneumatics

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Tuesday, September 21, 2010

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Circuit Diagram Structure

Control
Section

Electropneumatics

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Power
Section

Tuesday, September 21, 2010

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Feeding a work piece


In this application, cans will be
closed with a cover. The
definition of the process is:
The starting position of the
piston rod of the cylinder is the
rear end position. By pressing
and holding a push button, the
cover shall be pressed onto the
can. After releasing the push
button the piston rod of the
cylinder shall move back to the
rear end position.
Electropneumatics

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Tuesday, September 21, 2010

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Project 1: Information phase
Principles of circuits
Please refer to the video to get some information
regarding the principles of Electro-Pneumatic
circuit diagrams:
Principles of Electro-Pneumatic circuits

Electropneumatics

Pneumatic circuit diagram


Wiring diagram

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Tuesday, September 21, 2010

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Project 1: Information phase Pneumatic circuit

Electropneumatics

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Tuesday, September 21, 2010

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Project 1: Information phase Wiring diagram

Electropneumatics

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Tuesday, September 21, 2010

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Direct Control
Project 1: Solution

Electropneumatics

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Tuesday, September 21, 2010

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Heavy Work piece feeding

Work piece fed using a double acting cylinder.


The piston rod is extended when an electrical push button is pressed
and returned to initial position when push button is released.
5/2 way single solenoid valve is used to control the cylinder.
The Solenoid should be actuated indirectly.
Electropneumatics

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Tuesday, September 21, 2010

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Indirect Control

1V1

???

???

Electropneumatics

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Tuesday, September 21, 2010

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Indirect Control
Project 2: Solution

1V1

+
-

Electropneumatics

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Tuesday, September 21, 2010

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Heavy Work piece feeding

Work piece fed using a double acting cylinder.


The piston rod is extended when an electrical push button (S1) is
pressed and kept extended until another push button (S2) is pressed
to retract the piston rod to initial position.
5/2 way single solenoid valve is used to control the cylinder.
Electropneumatics

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Tuesday, September 21, 2010

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Electrical Latching

Electrical lacing circuits are divided in on- and off


dominant. Please refer to the video to see the basic
function
Electropneumatics

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Tuesday, September 21, 2010

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Memory Circuit- Dominant Reset


1A

+24V

START
4

1Y1

K1

K1

RESET

K1

1Y1

0V

2
3
Electropneumatics

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Tuesday, September 21, 2010

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Memory Circuit- Dominant Set


1A

+24V

START

K1

K1

2
RESET

1Y1
5

3
1

K1

1Y1

0V

2
3
Electropneumatics

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Tuesday, September 21, 2010

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Stroke Dependent Control


(Automatic Return)

Work piece fed using a double acting cylinder.


The piston rod is extended when a push button is pressed.
Piston rod returns to initial position when a limit switch at forward
position is switched.
Electropneumatics

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Tuesday, September 21, 2010

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Stroke Dependent Control


(Automatic Return)
+24V

1A

A2

START

K1

K1

2
A2

1Y1
5

3
1
K1

1Y1

0V

2
3
Electropneumatics

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Tuesday, September 21, 2010

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Heavy Work piece feeding


Continuous
operation
1A
LS1

LS2

1. Piston moves forward when


it reaches 1B1
50%

1V1
4

1Y1
1

Electropneumatics

2. Return to initial position


automatically when piston
moved to 1B2
3. Continuous cycle starts with
Start switch
4. Continuous cycle stops with
Stop switch
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Tuesday, September 21, 2010

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Continuous operation
1A

LS1

LS2

+24V

START

K2

50%
STOP

K2

K1

LS1

LS2

K1

1V1
4

1Y1
5

3
1

K2

K1

0V

2
3
Electropneumatics

1Y1

Nikini Automation Systems (Pvt) Ltd

4
5
Tuesday, September 21, 2010

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Memory Circuit with


Double Solenoid Valve
1A

+24V

S2

1Y1

1Y2

50%

S1

1V1
4

1Y1

1Y2
5

3
1

0V
Electropneumatics

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Tuesday, September 21, 2010

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Heavy Work piece feeding


Continuous operation

1. Piston moves forward when


it reaches 1B1
2. Return to initial position
automatically when piston
moved to 1B2
3. Continuous cycle starts with
Start switch
4. Continuous cycle stops with
Stop switch
Electropneumatics

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Tuesday, September 21, 2010

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Continuous operation with


Double Solenoid Valve
+24V

START

K1

STOP

K1

LS2

LS1

K1

1Y1

1Y2

0V

2
3
Electropneumatics

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Tuesday, September 21, 2010

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Timers

Electropneumatics

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Delay On Timer
S1 ON; T1 contact
turns on after a delay
S1 OFF; Immediately
T1 contact turns off

S1

Delay

T1
Contact
Electropneumatics

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Tuesday, September 21, 2010

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Delay Off Timer


S1 ON; T1 contact ON
S1 OFF; T1 contact
turns off after a delay

S1

T1
Contact

Electropneumatics

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Delay

Tuesday, September 21, 2010

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Counter

Electropneumatics

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Tuesday, September 21, 2010

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Counter
Up counter
S1(Pulse); C.V =>+1
R1(Pulse); C.V => 0
C.V >= P.V; C1
contact switches

Electropneumatics

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Tuesday, September 21, 2010

Continuous operation

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1. Piston moves forward after


pausing 2 Sec at 1B1
2. Return to initial position
automatically when piston
moved to 1B2
3. Continuous cycle starts with
Start switch
4. Continuous cycle stops with
Stop switch or stops
automatically after 5 cycles
5. S3 detent Switch is used to
pause the cycle.
Electropneumatics

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Tuesday, September 21, 2010

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Timer-Counter Exercise

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Timer-Counter Exercise

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

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Multi Actuator Systems


Sequential logic control
Combinational logic control

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

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Sequential control

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

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Vertical Displacement
2A (B)

1A
(A)

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

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Design steps
1.
2.
3.
4.
5.

Sketch the system


Identify the sequence
Design the (pneumatic) power circuit.
Identify the input signals & Output Signals
Design the control circuit according to the
control requirement.
6. If there are signal overlaps, necessary actions
should be taken to overcome signal overlap
problems.
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Displacement-step diagram

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

1A+ 2A+ 1A- 2A- With Single


Solenoid valves
1A (A)

2A (B)
1S1

1S2

2S1

50%

50%

1V1

2S2

2V1

2Y1

1Y1
5

Pneumatic Circuit
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Solenoids should be actuated since the valves are


spring returned.

Electropneumatics

Action
1A1+
2B1+
1A12A1-

Output
1M1 (Set)
2M1 (Set)
1M1 (Reset)
2M1 (Reset)
Nikini Automation Systems (Pvt) Ltd

Triggered by
1S1 & 2B1
1B2
2B2
1B1
Tuesday, September 21, 2010

Nikini

1A+ 2A+ 1A- 2A- With Single


Solenoid valves: with limit switches
1

+24V

START

K1

2S1

1S2

K2

2S2

K1

K1

K2

1S1

K2

1Y1

2Y1

0V

2
5
Electropneumatics

4
6
Nikini Automation Systems (Pvt) Ltd

Electrical Circuit
Tuesday, September 21, 2010

Nikini

1A+ 2A+ 1A- 2A- With Single


Solenoid valves: with sensors

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini
1A+ 2A+ 1A- 2A- With Double
Solenoid valves
1A (A)

2A (B)
1S1

1S2

2S1

50%

50%

1V1

2V1

1Y1

1Y2
5

2S2

2Y1

2Y2
5

3
1

Pneumatic Circuit
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Previous problem, now with double solenoid


valves.
In this case four outputs are there.

Electropneumatics

Action
1A1+
2B1+
1A12A1-

Output
1M1
2M1
1M2
2M2
Nikini Automation Systems (Pvt) Ltd

Triggered by
1S1 & 2B1
1B2
2B2
1B1
Tuesday, September 21, 2010

Nikini

A+ B+ A- B- With Double
Solenoid valves

Electrical Circuit
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Drilling Application
2.0
Drill Cylinder

Limit switches to
detect end limits of
cylinder movement

Clamp
Cylinder

1.0

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

1A+ 2A+ 2A- 1A- With Single


Solenoid valves

Pneumatic Circuit
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Drilling -Control diagram

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

1A+ 2A+ 2A- 1A- With Single


Solenoid valves

Electrical Circuit
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

1A+ 2A+ 2A- 1A- With Double


Solenoid valves
1A (A)

2A (B)
1S1

1S2

2S1

50%

50%

1V1

2V1

1Y1

1Y2
5

2S2

2Y1

2Y2
5

3
1

Pneumatic Circuit
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

1A+ 2A+ 2A- 1A- Double


Solenoid valves-Cascade Method

Electrical Circuit
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

1A+ 2A+ 2A- 1A- Double


Solenoid valves-Shift Register
1

+24V

START

K1

1S1

1S2

K2

K1

2S2

K3

K2

2S1

K4

10

S2

K1

11

K2

12

K3

13

K4

K3

K4

K2

K3

K1

K4

K2

K1

K3

K4

1Y1

2Y1

2Y2

1Y2

0V

2
3
10

4
5
11

6
7
12

1
8
13

Electrical Circuit
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Modern Electropneumatic Control


Systems
The most important objectives in all
developments in electropneumatics:

Reduction of overall costs of an


electropneumatic control system
Improvement of the system's performance data
Opening up of new fields of application

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Cost Reduction
The design of present-day electropneumatic
control systems is primarily aimed at
reducing the cost of:

Electropneumatics

project planning
installation
commissioning
maintenance.

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Improvement of the system's


performance data

Examples of how the performance data of


pneumatic components can be improved
include:
Reducing cycle times by increasing motion
speeds
Reducing mounting space and weight
Integration of additional functions, such as
linear guides
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Opening up of new fields of


application

Applications in which speeds, positions and forces are


continuously set and monitored by an electrical control
system have so far been the preserve of electrical and
hydraulic drives.
The development of low-cost proportional valves and
pressure sensors makes it feasible today to use pneumatic
drives in many applications.
A new market for pneumatics is emerging as a result.
Although this market is small in comparison with the
market for classical electropneumatic controls, it is
characterized by strong growth.

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Proportional pneumatics
Proportional pneumatics is primarily used in
the following fields of application:
Continuous adjustment of pressures and forces
Continuous adjustment of flow rates and speeds
Positioning with numerically controlled drives,
such as in robotics

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Proportional pressure regulating


valves

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Proportional pressure regulating


valves

A proportional pressure valve converts a


voltage, its input signal, into a pressure, its
output signal.
The pressure at the output to a consuming
device can be adjusted continuously from 0
bar to a maximum of, for example, 6 bar.

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Proportional directional control


valves

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Proportional directional control


valves

A proportional directional control valve combines


the properties
electrically actuated switching directional control valve
Electrically adjustable throttle (Flow control valve)

The connections between the valve ports can be


opened and shut off.
The flow rate can be varied between zero and the
maximum value.

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Proportional directional control


valves

A proportional directional control valve allows


continuous adjustment of the valve flow rate
=> continuous adjustment of the speed of travel of the
piston rod of a pneumatic cylinder

The speed characteristic can be optimized


Enables high speeds with gentle acceleration and
braking

Applications are found in conveying sensitive


goods (for example in the food industry).
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Optimized valves for block


mounting
Improved dynamic response

Through short switching times and high flow rate

Reduced compressed air consumption


Through reduced volume of air between valve and
drive unit

Reduced cost of the power supply unit


Through lower electrical power consumption

Less mounting space and minimized weight

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Optimized valves for block


mounting

Particularly low-loss air ducting


Very compact dimensions
Low cost.
A block may consist of the following:
Directional control valve modules
Modules for pneumatic connection
Modules for electrical connection

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Optimized valves for block


mounting
a) Valve module

b) Air supply and


silencer mounting
on an end face

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

c) Air supply and


silencer mounting
on underside
Tuesday, September 21, 2010

Nikini

Electrical connection of valve blocks


and valve terminals

a) Individual connection
with separate connector
for each solenoid coil
b) Multi-pin plug connection
c) Fieldbus connection
d) Actuator-sensor interface

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Electrical connection of valve blocks


and valve terminals
1. With no additional connection module, each coil is
connected individually via a separate cable socket.
2. Module for multi-pin connection: all solenoid coils are
connected to a single multi-pin plug within the valve
terminal .
3. Module for fieldbus connection: all solenoid coils are
connected to a fieldbus interface within the valve
terminal.
4. Module for AS-i connection (actuator-sensor interface):
all solenoid coils are connected to the two interfaces for
connection of the actuator- sensor bus within the valve
terminal.
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Modern installation concepts


The use of advanced components in electropneumatics
allows valves to e combined in valve terminals.
The contacts of the solenoid coils engage directly into the
corresponding connection sockets on the valve terminals.
The advantages are as follows:
No need for terminal boxes and associated terminals
strips.
Faulty directional control valves and sensors can be
replaced without having to be disconnected from and
reconnected to terminals.
Wiring effort is reduced
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

a) Valve terminal
and separate
sensor connection unit

b) Valve terminal
with integrated
sensor connection unit
and integrated PLC

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Layout of a Fieldbus system


The programmable logic controller and the
valve terminals each have an interface by
means of which they are connected to the
fieldbus.
Each interface consists of a transmitter
circuit and a receiver circuit.
The fieldbus transfers information between
the PLC and the valve terminals.
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Layout of a Fieldbus system

The power for operating the


valves and sensor is transmitted
via the same cable.
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Example Field BUS:AS-i

Directional control valve


with AS interface
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Reducing wiring effort

a) Valve blocks with


conventional wiring
Electropneumatics

b) Valve terminal with multipin plug connection


Nikini Automation Systems (Pvt) Ltd

c) Valve terminal with fieldbus


connection
Tuesday, September 21, 2010

Nikini

Documentation for an
electropneumatic control system
Positional sketch
Function diagram or function chart
representation of the control sequence

Pneumatic and electrical circuit diagram


representation of the interaction of all components

Terminal allocation list


representation of the wiring allocation of terminal strips
in switchboxes and terminal boxes

Parts lists
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Positional sketch
Clamp Cylinder

Sensors

Metal Sheet

Bending Cylinder

Sheet-metal bending device


Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini
Four steps are required for the bending operation:
Step 1:
Advance piston rod of cylinder 1A (clamp workpiece)

Step 2:
Advance piston rod of cylinder 2A (bend metal sheet)

Step 3:
Retract piston rod of cylinder 2A (retract bending
fixture)

Step 4:
Retract piston rod of cylinder 1A (release workpiece)

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Displacement-step diagram

The movements of the piston rods are shown.


The individual movement steps are numbered consecutively from left
to right.
If there is more than one power component, the movements of the
piston rods are plotted one below the other.
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Displacement-time diagram

The movements of the piston rods are plotted as a function


of time.
This highlights the different lengths of time needed for
individual steps.
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Function Chart

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Electrical Signal Processing

Signal Input
Electropneumatics

Signal processing
Nikini Automation Systems (Pvt) Ltd

Signal output
Tuesday, September 21, 2010

Nikini

Programmable Signal Processing


Programmable
Microprocessor
system

Signal Input
Electropneumatics

Signal processing
Nikini Automation Systems (Pvt) Ltd

Signal output
Tuesday, September 21, 2010

Nikini

Programmable logic controllers


Programmable logic controllers (PLCs) are
used for processing of signals in binary
control systems.
The PLC is particularly suitable for binary
control systems with numerous input and
output signals and requiring complex signal
combinations.

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

PLC driven Electric drives

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Advantages of PLC
Greater reliability and longer service life
no moving contacts
Less project planning work
tested programs and subprograms can be used for a
number of different control setups
but each relay control circuit has to be wired and tested
from scratch
Faster control development
programming and wiring can be carried out in parallel
Simpler monitoring of stations by a higher-level host
computer
a programmable logic controller can easily exchange
data with the host computer
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

PLC is the most cost-effective solution for


implementation of a signal processing system.

hardware costs
project planning
setting up
commissioning
maintenance

Today's electropneumatic control systems are


therefore almost always equipped with a PLC.
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Review







Introduction to Electro-pneumatics systems


Switches and Sensors
Recognizing and drawing of electrical symbols
Electrical Signal processing
Electro-pneumatic actuators
Solving simple control problems using electropneumatics
 Solving control problems using multi actuator
electro-pneumatic systems
Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Questions??

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

Nikini

Electropneumatics

Nikini Automation Systems (Pvt) Ltd

Tuesday, September 21, 2010

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