Faculty of Engineering Technology Department of Mechanical Engineering Technology

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Department of Mechanical Engineering Technology Revision No. 1

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Effective Date 00/00/0000
FACULTY OF ENGINEERING TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING TECHNOLOGY
Course Code & Name BNJ 20903 (SOLID MECHANICS )
Title of Experiment The Tower Challenge
Date of Experiment 18 MAY 2017

Programme BNM(1)
Group
Name Matric No.
1.NURFARHANI BINTI HISHAMUDIN AN160051
Group Members 2.NUR SYUHADA BINTI MOHD YAACOB AN160006
3.NORFATIHAH BINTI ABDUL RASHID AN160136
4.NUR LYANA SYAHIRAH BINTI SURIANSAH AN160166
5.
1.DR. NOFRIZALIDRIS BIN DARLIS
Instructor Names
2.
Introduction
Objectives
Project outcome
Project statement
Theory related
Analysis/Sample calculation
Assessment Conclusion
References
Total
Faculty of Engineering Technology Page No. 2 / 15

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1. INTRODUCTION (10 MARKS)
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. This pneumatically assisted valve action is in contrast to a direct electric
action in which each pipe's valve is opened directly by an electric solenoid which is attached to the
valve. Electro-pneumatic also widely use because it has higher reliability which means it has fewer
moving parts subject to wear. It is also lower planning and commissioning effort particularly for
complex controls. Next, lower installation effort, particularly when modern components such as
terminal are used and it is simpler exchange of information between several controllers.
Electro pneumatics is now commonly used in many areas of Industrial low cost automation.
They are also used extensively in production, assembly, pharmaceutical, chemical and packaging
systems. There is a significant change in controls systems. Relays have increasingly been replaced
by the programmable logic controllers in order to meet the growing demand for more flexible
automation.
In this experiment, series and parallel electrical circuits is being used to conduct the
experiment. Students understand and know the drawing of the basic electro-pneumatics circuit also
know how to install the circuits. OR and AND components is widely used in this experiment to
show the understanding of students in installing and test run the circuits. A 5/2 way valve double
solenoid is being used in this experiment. The function of the components is to use to isolate and
simultaneously bypass a passage way for the fluid which for example should retract or extend a
double-acting cylinder.
An electro-pneumatic action requires less current to operate than a direct electric action. This
causes less demand on switch contacts. An organ using electro-pneumatic action was more reliable

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in operation than early direct electric organs until improvements were made in direct electric
components.
A disadvantage of an electro-pneumatic organ is its use of large quantities of thin perishable

leather, usually lambskin. This requires an extensive "re-leathering" of the wind chests every
twenty-five to forty years depending upon the quality of the material used, the atmospheric
conditions and the use of the organ.
Pneumatic circuits can be controlled by electric circuits. The interface between these two
circuits is a solenoid valve. Solenoid valves perform the same function as normal pneumatic valves
but there are operated electrically. Inside the solenoid valve, there is a coil of wire through which
an electric current is passed. It produces a magnetic field which attracts an iron armature. The
movement of the armature operates the valve. Electro-pneumatic control consists of electrical
control systems operating pneumatic power systems. In this solenoid valves are used as interface
between the electrical and pneumatic systems. Devices like limit switches and proximity sensors
are used as feedback elements.

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2. OBJECTIVES (5 MARKS)
i. Draw a basic electro-pneumatic circuit, install and test run it to move an

actuator.
ii. Identify and operate a few types of electro-pneumatic components.
iii. Install the serial and parallel electrical circuits for OR/AND functions.
3. SCOPE (5 MARKS)
i. Understand the function of OR/AND components.

ii. Understand the function of a 5/2 DCV double solenoid.
iii. Practice safety in laboratory to avoid any accident.
iv. Draw and install the components based on the lab sheet.
v. Can test run the components.
4. SAFETY PRECAUTION (5 MARKS)
4.1 General rule

1. Each user whether students and staff should obey with all the safety regulations
outlined in the laboratory.
2. Every user should know where the fire extinguisher and first-aid kit. Get the
information from lecture / instructor about procedure using the equipment and
must know and comply with the safety aspects of each equipment.
3. Make sure get the permission from the laboratory supervisor / lecturer / instructor
in charge before using the equipment or the start of practice.
4. You are not allowed to eat, drink, smoke, make noise, joking and sleep in the

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laboratory.
5. Bag and shoes should be placed outside the laboratory that has been prepared in
accordance with the rules of each section of the laboratory.
6. Wear appropriate clothing and safe as outlined in the dress code while in a
university laboratory.
7. Make sure you know the rules properly and safety before using the machine and
the necessary equipment. Please refer to the officer on duty in the lab.
8. Use safety equipment (Personal Protective Equipment) when using the machine
or equipment needed.
9. Report immediately to the officer on duty in case of any item that is not on
desired machinery or equipment such as damage, injury, accident, electrical
damage, etc.
10. After using all the machinery and equipment needed, you should always ensure
that the working environment was cleaned, while the equipment used originally to
be restored in place that has been provided.
11. Must always ensure that the power switch machines and equipment that have
been used are turned off before leaving the laboratory or workshop.
12. All laboratory equipment is not allowed to be carried out without written
authorization (Laboratory Equipment Loan Authorization Form) approved by the
Supervisor of Laboratory.
4.2 Specific Rules Electro-Pneumatics Section

1. Put bags on the place that has been provided outside the classroom laboratory.
2. Make sure you know the rules properly and safely before using the machine and
the necessary equipment. Please refer to the officer on duty in the lab.
3. Make sure the power supply for the electro-pneumatic circuit is switch off when
installing the circuit.

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4. Recompile equipment that was used in the place of origin based on color, code
and lockers.
5. Make sure the power switch machines and equipment that have been used are
turned off before leaving the laboratory.
6. Write your name (one group representative) on Form Record Machine.
5. PROCEDURES (20 MARKS)
TASK 1
1. Read and understand the instruction thoroughly and sketch the pneumatic and electric
circuit drawing.
2. Connect the pneumatic circuit and electric circuit as shown in Figure 6.1
3. Validate the pneumatic circuit and electric circuit for any misconnection. Make sure to
recheck again after connect the component.
4. Turn the pneumatic power unit ON.
5. Turn the electrical power unit ON.
6. Press push button A and verify if the piston rod of the pneumatic cylinder extends.
7. Press push button B and verify if the piston rod of the pneumatic cylinder retracts.
8. After you complete the experiment, turn OFF of the pneumatic power unit and electric
power unit.
TASK 2 (BASIC LOGIC FUNCTION)
1. Read and understand thoroughly before start the experiment

2. Sketch the pneumatic and electric circuit drawing and check with the lecture for
confirmation
3. Connect the pneumatic circuit and electric circuit as shown in Figure 6.2

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4. Validate the pneumatic circuit and electric circuit for any misconnection. Make sure
recheck again to avoid any accident.
5. Turn the pneumatic power unit ON and turn the electrical power unit ON.
6. Press and hold push button A. Verify if the piston rod of the pneumatic cylinder extends.
7. Release push button A. Verify if the piston rod of the pneumatic cylinder extends.
8. Record your observation.
9. Press the switch push Button B and verify if the piston rod of the pneumatic cylinder
retracts.
10. Replace the current electric circuit to the electrical circuit shown in Figure 6.3(AND
UNIT). Repeat procedure #3 to #7. Record the observation
11. After you complete the experiment, turn OFF of the pneumatic power unit and electrical
power unit.
TASK 3
1. Read and understand thoroughly before start the experiment.

2. Sketch the pneumatic and electric circuit drawing and check with the lecture. Make sure
use capacitive sensor for this task.
3. Connect the pneumatic circuit and electric circuit as shown in Figure 6.4.
4. Validate the pneumatic circuit and electric circuit for any misconnection. Make sure install
the component in the correct terminal.
5. Turn the pneumatic power unit ON and turn the electrical power unit ON.
6. Press push button A. Verify if the piston rod of the pneumatic cylinder extends.
7. Verify if the sensor detect or not the piston
8. Record your observation.
9. Press the switch push Button B and verify if the piston rod of the pneumatic cylinder
retracts.

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10. After you complete the experiment, turn OFF of the pneumatic power unit and electrical
power unit.
6. ANALYSIS / OBSERVATION (25 MARKS)
Task 1
In task 1, we do the experiment of 5/2 double solenoid and double acting cylinder. The
function of 5/2 double solenoid is The double solenoid valve is reversed when voltage is applied to
a solenoid coil and remains in this switching position after the signal is removed until an opposed
signal is applied. The presence of switching signals is shown by the LEDs in the terminal
housings. The valve is equipped with a manual override.
When push button A (PBA) is press the 5/2 double solenoid changes over. The air pressure
will increase in the left part and the piston will extend. The piston travels out and remains in the
final forward position. The 5/2 directional control valve will remain in the last position because it
is double solenoid valve and has no return spring. The piston will retract if PBC is press.
When the push button PBA is released and PBC is pressed. Opening of Push button PBA
de-energizes. Closing of PBC energizes the solenoid and the piston returns to its original position
as a result of changeover of the 5/2 way valve. The 5/2 double solenoid will not switch over if
there is an active opposing signal. For example, if solenoid is switched on and a signal is given to
solenoid , there will be no reaction as there would be an opposing signal.
Task 2
In task 2 experiment, the 5/2 double solenoid is used. There are 3 components will be added
to make the system function smoothly. The 3 components are OR Unit, AND Unit and limit
switch.

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First, we use OR Unit. In this experiment we apply parallel circuit. When the PBA or PBB is
press the piston will extend. It is to return when both are released. When PBA or PBB are pressed
the solenoid is energized. The 5/2 double solenoid switches over and the piston travels to the final
forward position. When both the PBA and PBB switches are released, the signal is removed from
solenoid and when the piston touch the limit switch the cylinder travels back to its original
position.
Second, we use AND Unit. In this experiment we apply series circuit. The system will fully
function when the both PBA and PBB are press together. When PBA and PBB are press the
solenoid is energized. The 5/2 double solenoid switches over and the piston will extend until the
maximum position before it return to the original position. When the piston touch the limit switch
the piston will automatically retract.
Task 3
In task 3 experiment, the capacitive sensors use an alternating voltage which causes the
charges to continually reverse their positions. The moving of the charges creates an alternating
electric current which is detected by the sensor. The amount of current flow is determined by the
capacitance, and the capacitance is determined by the area and proximity of the conductive objects.
Larger and closer objects cause greater current than smaller and more distant objects. The
capacitance is also affected by the type of nonconductive material in the gap between the objects.
When PBA is press the energy will be transfer to the capacitive sensor and the capacitive
sensor will store the energy. And then the solenoid will energizes and the piston is travel to the
forwad position. The sensor is activated because of moving of the charges in the alternating
electric current. The PBA is unactive so that the PBB will active and the piston will retract. If the
capacitive sensor cannot detect, the piston will not return to its original position.

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7. DISCUSSION (10 MARKS)
Figure 7.1
Push button A Push Button C Double acting cylinder

(extend/retract/no change)
Not pressed Not pressed No change
Not pressed Pressed No change
pressed Not pressed Extend
pressed pressed Retract
Figure 7.2

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Push button A Push button B Double acting cylinder

(extend/retract/no change)
Not pressed Not pressed No change
Pressed Not pressed No change
Not pressed Pressed No change
Pressed Pressed Extend
Figure 7.3
Push button A Push button B Double acting cylinder

(extend/retract
Switch button Extend Retract

A Pressed Not pressed
B Pressed Not pressed
Limit switch Not touched Touched

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Figure 7.4
Push button A Push button B Sensor Double acting-

cylinder
(extend/retract/no
change)
Not pressed Not pressed Not detected No change
Pressed Not pressed Detected Extend
Not pressed Pressed Detected Retract
Pressed Pressed Not detected No change

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8. CONCLUSION (10 MARKS)
After the first class, we had finished our first electro-pneumatic practice 1. But there is a
few mistake and problem when carry out the project such as wrongly install components, use
components that are not correct and so on. But this can be overcome when we reread the
instructions given. We should know how to control the air pressure, be aware with the limit of air
pressure because it caused explosion. We discovered the importance of regulatory compliance and
safety in the laboratory so that accidents can be avoided and the work can be done well and
comfortable. We also need have to decide and select the appropriate components for a particular
experiment and always be discipline in the workshop. Then, should follow the instruction to avoid
the incident. In addition, I also improve some skill in using equipment available in the laboratory.
Therefore, before I start a work I will learn and know something so that the system will run
smoothly and perfectly. The objectives the group set out to accomplish were done and we have a
deeper understanding of sequencing of pneumatic components and circuits. We also explored the
various safety measures that we can implement as this necessary in an industrial setting. We also
looked into how we could improve the set up by introducing a counter.

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9. RECOMMENDATION (5 MARKS)
Our recommendation is we can know how to construct accurately and can arrange the
component of electropneumatic circuit systematically.Next, are components that gave been
damaged mixed with the component that can work. Then we can know how to report and explain
briefly the operation of this experiment in group.we can learn to find out the correct component
and equipment.Components should be separated so that students do not use these components to
build the circuit. Components need to be replaced with new components so that students can use
enough components to build the circuit mainly used by many groups. We also explored the various
safety measures that we can implements as this necessary in an industrial setting. We also looked
into how we could improve the set up by introducing a counter.
10. REFERENCES (5 MARKS)
i. https://en.wikipedia.org/wiki/Electro-pneumatic_action (Wednesday. 15/03/2017)

ii. https://www.scribd.com/presentation/15339920/Pneumatic-ElectroPnuematic-Jan2008
(Wednesday. 15/03/2017)
iii. http://www.proconsol.co/2011/02/16/how-does-a-52-way-directional-valve-work/ (Saturday.
18/03/2017)
iv. http://www.lionprecision.com/tech-library/technotes/cap-0020-sensor-theory.html

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Faculty of Engineering Technology Page No.

Department of Mechanical Engineering Technology Revision No. 1