Electro-Pneumatic

Module 1: Introduction to Electro-

pneumatics

PREPARED BY

Academic Services
August 2012

© Applied Technology High Schools, 2012

ATM-414 – Electro-Pneumatics

Module 1: Introduction to Electro-

pneumatics

Module Objectives
After the completion of this module, the student will be able to:
1- Explain all safety precaution when working with electro-pneumatics.
2- Explain the concept of signal flowing in electro-pneumatics.
3- Identify the advantages and disadvantages of the elector-
pneumatics.

Module Contents

Sr Topic Page No.

1 Introduction to electro-pneumatics 3

2 Signal flow in electro-pneumatics 4

3 Advantages of electro-pneumatic systems 5

4 Components of electro-pneumatic system 6

5 Safety and operation 12

6 Practical task 1 13

7 Practical task 2 17

8 Practical task 3 18

9 References 24

2 Module 1: Introduction to electro-pneumatics

ATM-414 – Pneumatic systems

1 Introduction to electro-
pneumatics

Electro-pneumatic is widely used in

many areas of industrial
automation. Production, assembly,
and packaging systems worldwide.
These systems are driven by
electro-pneumatic control systems.
Fig.1.1 (a) and Fig1.1 (b) show
different applications of electro-
pneumatic machines.
(a)

In electro-pneumatics, the
pneumatic components are
controlled by using electrical and
electronic circuits. Electronic and
electromagnetic sensors, electrical
switches and industrial computers
are used to replace the manual
(b)
control of a pneumatic system.

Fig.1.1
(a): Milk filling machine
(b): Yogurt filling machine

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ATM-414 – Electro-Pneumatics
`
2 Signal flow in electro-pneumatic control system

The signal flow diagram of Fig. 1.2 illustrates the signal flow within an
electro-pneumatic system.
1. Signal input: This signal is usually generated from sensor or switch.
2. Signal processing: the signal is processed in the processing station such
as OR gate, AND gate or time delay valve.
3. Signal output: the signal forms as a link between the signal control
section and the power section
4. Command execution: it takes place at high power level either for:
 High speed-fast ejection of product.
 Apply high force as in power presses.

Fig. 1.2: Signal flow and components of an electro-pneumatic control

system

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ATM-414 – Pneumatic systems

3 Advantages of electro-pneumatic systems:

Below are some advantages of electro-pneumatic systems
1. Greater reliability.
Less moving parts subjected to wear compared to mechanical
control systems.
2. Reduced installation complexity.
Less components and hoses, leads to less effort in planning and
commissioning especially with large and complex systems.
3. The control system can be easily modified and adapted.
It is easier to change wiring and modify programs rather than
changing mechanical components and hose networks.
Example: the AND gate is replaced with logic and through using
electrical switches.
4. Easy handling.
Less complexity
5. Secure mounting.
Fewer hoses
6. Environmentally-friendly coupling system.
Less lubrication require

4 Components of electro-pneumatic system

The electro pneumatic system is normally consists of the following items:
1. DC power supply.
2. Switches.
3. Relays.
4. Solenoid valves.
5. Sensor.

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ATM-414 – Electro-Pneumatics

4.1 DC Power Supply

The power supply is used to reduce and convert the 230 V AC to a 24 V DC
(inside ATHS laboratories) as shown in Fig.1.3

Figure 1.3 power supply

The power supply components which are shown in Fig. 1.4 have the
following functions:
 The transformer reduces the main voltage (230 to 24 volt).
 The rectifier converts the AC voltage to DC voltage.
 The stabilizer is used to smooth and maintain constant voltage at the
output

Fig.1.4 electric diagram of the power supply

The following criteria play commonly an important role is selecting the

power supply:

 The magnitude of voltage and current it can supply.

 How stable its output voltage or current is under varying load
conditions.
 Whether it provides continuous or pulsed energy.

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ATM-414 – Pneumatic systems

4.2 Switches
Switches are installed in an electric circuit to connect or interrupt the
electric current.
These switches are divided into:
1- Control switches: keep the selected position such as detent switches.
Push button switches: maintain the selected position as long as the switch
is activated.
In this module, three types of switches will be discussed:
a. Push button switches.
b. Detent switches.
c. Limit switches.
(a) Push button switches
These switches are activated manually and used connect or disconnect the
electric current in he control circuit. There are three typed of the push
button switches:

1- Normally open contact

(make)
In the case of a normally open
switch Fig.1.5.a, the circuit is
open if the switch is in its initial
position
(a) (b)
Pressing the pushbutton results in
closing the circuit and then the
current will flow to load. When
the plunger is released the spring
will returns the switch to it initial
position.

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ATM-414 – Electro-Pneumatics

2 Normally close contact

(break)
In the case of the normally closed
switch Fig. 1.5.c, the circuit is
closed when the switch is in its
initial position. The circuit is (c) (d)

interrupted by pressing the

pushbutton. Fig.1.5.d shows the
ISO symbol of the push button N/C.
2 4
3 Changeover contact (two-
way)
1
The change over contact Fig. 1.9-c
combines the function of the (e) (f)

normally open and normally closed.

Changeover contacts are used to
close one circuit and open another
circuit in one switching operation.

In the (ATHS) labs, these types of

(g)
switches are combined in one switch
Fig.1.5:
block as illustrated in figure 1.5.g.
(a): push button switch (N/O)
(b): ISO symbol of the normally
open push button switch
(c): push button switch (N/C)
(d): ISO symbol of the normally
closed push button switch
(e): changeover switch (two way)
(f): ISO symbol of the changeover
switch
(g): Switch block

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b Detent switches
These switches keep the selected
position; the switch position remains
unchanged until a new switch position
is selected. It is called detent switch or
a latching switch. Fig.1.6.a and (a)
Fig.1.6.b show the ISO symbol of the
normally open detent switch and
normally closed detent switch
respectively.
Detent switches also designed to be as (b)
normally open, normally closed or
changeover switches.

In the (ATHS) labs, the detent switches

are included in the same switch block
with pushbutton switches, as shown in
(c)
Fig. 1.6.c
Fig. 1.6:
(a): ISO symbol of normally
open detent switch
(b): ISO symbol of normally
closed detent switch
c Limit switches
(c): Switch block
The limit switch (Fig.1.7.a) is actuated
when a machine part or a work-piece is
in a certain position. Normally,
actuation is affected by a cam or
cylinder piston.

Limit switches are normally changeover (a) (b)

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ATM-414 – Electro-Pneumatics

contacts and can be connected

according to the required control
circuit. The limit switch can be used in
circuit according to one of the
following:
 Normally open switch
 Normally closed switch
 Changeover switch
Fig. 1.7
.
(a): internal construction of the
limit switch
(b): ISO symbol of the limit
switch
(c): picture of the limit switch

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4.3 Relays
A relay is defined as an
electromagnetically actuated switch.
When the voltage is applied to a
solenoid coil terminals (A1, A2) in
Fig.1.14, it will become an
electromagnet which in turn attracts
the contacts of the relay either closing (a)
or opening them.
The spring returns the contacts to the
initial position immediately after
disconnecting the voltage at the coil
terminals. (b)
An ISO symbol of the relay and a lab
relay block is also illustrated in the
same figure.
Some advantages of a relay that:
 It can be used to switch one or
more contacts.
 To switch a high current circuit with
a low current circuit.
(c)
Fig. 1.8:
(a): Internal structure
(b): ISO symbol of the relay
(c): Relay block

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ATM-414 – Electro-Pneumatics

5. Safety and operation

The following points should be observed while working with electro-

pneumatic systems:

1. Pressurized air lines that

become detached can cause
accidents. Switch off pressure
immediately.
2. First connect all tubing and
secure before switching on
the compressed air.
3. Cylinders may advance or
retract as soon as the
compressed air is switched
on.
4. Do not operate the electrical
limit switch manually during
fault finding (use a tools
only).
5. Limit switches should be fixed
in such a way that they
contact the trip cam of the
cylinder only in the
determined direction.
6. Do not exceed the permissible working pressure.
7. Use only low voltages of ≤ 24 V.
8. Switch off the air and voltage supply before disconnecting the
circuit.

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6. Practical Task 1
Title:
Controlling an electric bulb lighting
using different types of switches
Objectives:
 Understanding and using the DC
power supply.
(a)
 The student should be able to use of
the pushbutton switches (NO and
NC).
 The student should be able to use of
detent switches (NO and NC).
 The student should be able to use of
changeover switch.
 The student should be able to
(b)
construct the circuit using the
FluidSim software
Background:
The student should know how to use
the Pushbutton, detent and changeover
switches that will be used to switch
on/off a lamp using different circuit
configurations.
Required components: (c)

1- DC power supply (Fig.1.9.a)

Fig. 1.9:
2- Indicator unit (Fig.1.9.b)
(a): Dc power supply
3- Switch block (Fig.1.9 c)
(b): Indicator block
4- Limit switch (Fig1.7 c)
(c): Switch block

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ATM-414 – Electro-Pneumatics

Procedures:
1. Prepare the components according to
the components list.
2. From the switch block, use a
pushbutton switch to connect the first
two circuits as in Fig.1.10.a
 Pushbutton switch, normally open.
Press the switch on/off and explain
what happens to the lamp.
……………………………………………………………
……………………………………………………………
……………………………………………………………
 Pushbutton, Normally closed switch.
Press the switch on/off and explain N.O NC
what happens to lamp. (a)
……………………………………………………………
……………………………………………………………
…………………………………………………………..
3. From the switch block, use a detent
switch to connect the second two
circuits as in Fig.1.10.b
 Detent switch, normally open. Press
the switch and note what happens to
the lamp.
……………………………………………………………
……………………………………………………………
……………………………………………………………

N.O N.C.
(b)

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 Detent switch normally closed. Press

the switch and note what happens to
the lamp.
……………………………………………………………
……………………………………………………………
…………………………………………………………..

4. Use a limit switch (as a changeover

switch) to connect the circuit as in
Fig.1.10.c

Press the switch and see how the switch

is used to control two circuits at a time.
Write your comments.
(c)
………………………………………………………………
……………………………………………………………… Fig. 1.10:
……………………………………………………………… (a): Push button switch
……………………………………………………………… (b): Detent switch
……………………………………………………………… (c): Changeover switch
………………………………………………………………
……………………………………………………………..
5. Turn the power off.
6. Dismantle and tidy up.
Conclusion

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Module 1: Introduction to electro-pneumatics 15
ATM-414 – Electro-Pneumatics

7. Practical Task 2
Title:
Indirect control of a lamp using a
pushbutton switch and a relay.
Objectives:
 Introduce the students to the use of
lab equipment.
Relay block
 Introduce the students to the use of
DC power supply.
 Introduce the students to the use of
the pushbutton switches (NO and
NC).
 Introduce the students to the use of
the relay and the associated
contacts (NO and NC).
Background:
The relay is an electromagnetically
operated switch; it will be used to
indirectly control a 24V lamp through
a pushbutton switch.
Required Components:
5- DC power supply
6- Indicator unit
7- Switch block
8- Relay block

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Procedures:
+24V 1 2
1. Connect the circuit according to circuit
shown in Fig.1.11.a, so the relay is a
3
normally open.
4
2. Switch on /off the pushbutton switch
and observe the lamp and also the LED A1 3
K1 K1
of the relay block. Explain what A2 4
happens to the lamp?
0V
……………………………………………………………………
……………………………………………………………………
2
………………………………………………………..……
(a)
3. Replace the pushbutton switch with a
+24V 3 4
detent switch and repeat the same
steps. Explain what happens to lamp.
3
………………………………………………………………
………………………………………………………………
4
………………………………………………………………
A1 1
4. Connect the circuit according to circuit K2 K2
shown in Fig.1.11.b, so the relay is in a A2 2

normally close mode.

0V
5. Switch on/off the pushbutton switch
and observe the lamp and the LED of
4
the relay block. Explain what happens (b)
to lamp.

…………………………………………………………….. Fig. 1.11:

……………………………………………………………… (a): Relay-Normally open

……………………………………………………………… (b): Relay-Normally closed

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ATM-414 – Electro-Pneumatics

6. Turn off the power

7. Dismantle and tidy up.

Conclusion

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8. Practical Task 3:
Title: Opening/closing the flow in a pipeline
The double acting cylinder (1A) in Fig. 1.12 is used to open and close the
main valve in a pipeline. Draw an electro-pneumatic circuit to control the
movement of cylinder (1A).
Hint: The valve is opened by pressing the pushbutton switch. When the
pushbutton is released the valve is closed.

Fig. 1.12

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ATM-414 – Pneumatic systems

Procedures:

1. Draw the elector-pneumatic circuit using the FluidSim software

2. Test the circuit functions against any errors or mistakes.

3. Construct the circuit on the workstation

4. Write down your notes and observations.

Pneumatic circuit Electric circuit

Observations

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ATM-414 – Electro-Pneumatics

Student’s notes

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Class work
1. Name three electrical components that will be used in the lab.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
2. What is the function of a D.C. power supply?
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
3. What are the main components of the D.C. power supply?
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
4. List the main types of switches in terms of function.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………

5. Explain the difference between a push button switch and a detent switch.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
6. Explain the difference between a pushbutton normally open switch and a
pushbutton normally closed switch.
……………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………

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ATM-414 – Electro-Pneumatics

7. Draw the ISO symbol of the following components:

a- Detent pushbutton switch, N/C and N/O

N/C N/O

b- Changeover switch

c-Relay

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ATM-414 – Pneumatic systems

Home Work

The circuit below illustrates a relay controlling three lamps indirectly,

answer the following questions:

1. What is the type of switch S1?

………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
2. How many relays are there in the circuit?
………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………..
3. What is the meaning of the symbols below circuit 1 and circuit 4?
………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………..
4. Explain what happens when switch S1 is activated.
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………
Module 1: Introduction to electro-pneumatics 23
ATM-414 – Electro-Pneumatics

9. References

1. Electro-pneumatic text book TP 201 2005 – Festo

2. Electro-pneumatic work book TP201 2005 – Festo

3. Electro-pneumatic work book TP202 advanced level – Festo

24 Module 1: Introduction to electro-pneumatics