LOW COST AUTOMATION

THROUGH
PNEUMATIC
SYSTEM
International Training Centre, Butibori

9001:2008
CERTIFIED INSTITUTE
By: Amol Khichade
 CONTENTS
 About Automation
 About Pneumatics
 Applications
 Advantages & Disadvantages
 Pneumatic Standards
 Classification of Pneumatic elements
 Applications of air cylinders
 Components of Pneumatics
 Comparison between Pneumatic, Electro-pneumatic &
PLC based control system
 Air pressure losses
 Malfunctions of Pneumatic system
 General safety measures
 Basics Pneumatic circuits
 What is Automation
•Automation is basically the delegation of human control
function to technical equipment for
•Increasing productivity
•Increasing quality
•Reducing cost
•Increasing safety in working condition.
Industrial Robots
Automated Guided Vehicle
Computer Numerical Control (CNC) Machine
Automation in Electronics Industry
Hydraulic System in Automobile
 INDUSTRIAL AUTOMATION

Electrical and
Pneumatics Hydraulics Electronics

In general, automation in industries are classified into

three categories.

Out of the above three, pneumatic systems are used in

achieving Low Cost Automation in industries,

1) To reduce labor cost,

2) To reduce machine investment cost
3) To increase productivity
4) To reduce human efforts
 What is Pneumatics ?

In Greek “Pneuma” means air.

Study (or) subject deal with “Pneuma” / compressed air is

called as “Pneumatics”.

Products that use compressed air as medium for operation

are called as “Pneumatic components”.
 What is Pneumatics ?
continued…

 Mechanisms which
use air pressure to
apply mechanical
force and Retracted
displacement (work) Cylinder

 Thepneumatic
devices we use are
basically binary
actuators – either
retracted or
extended Extended
Cylinder
Low Cost Automation
Pneumatics is widely used by SMEs for implementing
“Low Cost Automation”

1) To reduce machine investment cost

2) To reduce the process time
3) To increase productivity, and
4) To have consistent quality

Automation .mp4
Advantages and Limitations of Pneumatics

Advantages

 Simple

 Easy to control

 Can apply a lot of force from a small, light package

 Force is limited by air pressure and cylinder diameter

 The speeds and forces are infinitely variable

Advantages and Limitations of Pneumatics
continued…
Advantages

 Pneumatic tools when over loaded will stop and so safe,

as compared to electrical system.

 No fire hazard as in Electrical Systems. So can be

easily used in dangerous areas like mines.

 Simple in construction, the pneumatic system

components are easy to maintain & repair.

 The used air is exhausted. So no return lines as in

hydraulic system.
 Disadvantages

 Smooth and uniform speeds against loads are not

achievable as in Hydraulic systems.

 Beyond certain load usage of pneumatic system is

expensive.
FORM OF OUTPUT
1. Linear motion
2. Rotary motion
3. Semi-rotary motion

APPLICATIONS
Pneumatic equipments can be used for applications, where
operation cycles need certain routine functions like
1. Pushing
2. Pulling
3. Lifting
4. Feeding
5. Clamping
6. Pressing
7. Forming, etc.
APPLICATION AREAS
1. Air brakes of automobile & trains.
2. Air engine
3. Pneumatic drills
4. Pneumatic press, power press
5. Auto motional of assembly line like automobile industry,
packaging, bottling
6. Pneumatic vehicle cleaning
7. Anti aircraft weapon
8. Pneumatic launchers
9. Vacuum pump
10. Pressure regulator
11. Cotton mills
12. Dairies
13. Forge shops
14. Foundries
15. Metal forming
16. Paper mills
17. Printings
 Applications of
Pneumatic System
Pneumatic drill machine
Pneumatic suction machine
Pneumatic wrench
Pneumatic conveyor system
Pneumatic adjustable table
Pneumatic Jack
Pneumatic Brake
Pneumatic Clamp
A double acting cylinder is used for embossing slide rules
Pins are to be fed to the next processing station using a
double-acting cylinder
Pneumatically controlled press with a stamping die
Arrangement for pushing work-piece
Small riveting machine with lever
An application using a toggle
An application using a toggle
Work piece clamping in Hacksaw cutting machine
Pneumatic injection in plunger type moulding machine
Leak test automated using pneumatic cylinders
Endurance test of spring done using pneumatic cylinders
Door opening & closing mechanism using air cylinder
Punching operation on thin sheets with air cylinder
Pneumatic cylinders used for automation in drilling machine
Pneumatic cylinders used in line feeding automation
 PNEUMATIC STANDARDS

ISO 1219-1 Fluid power systems & components – Part 1:

Symbol for conventional use & data processing
applications.
ISO 1219-2 Fluid power systems & components – Part 2:
Circuit diagram
ISO 5599 Port marking of pneumatic directional control valves.
ISO 6432 Mounting dimensions of pneumatic cylinders: 8 to 25 mm
ISO 6431 Mounting dimensions of pneumatic cylinders: 32 to 320
mm.
CETOP RP41 Hydraulic & Pneumatic system circuit diagrams.
CETOP RP68P Identification code for ports and operators of pneumatic
control valve and other components.
ISO 8573 Quality classes of compressed air for general use
 Classification Of Pneumatic Elements
Pneumatic elements are classified into 5 groups as

5. Working elements
Air cylinders

4. Final control elements

Flow control valve, Quick exhaust valve

3. Control elements
Directional control valves like solenoid
valves, pilot operated valves

2. Signal elements
Push button valve, Roller lever valve

1. Source & Service elements

Source – Compressor & Reservoir
Service – Filter, Regulator, Lubricator
 1. Source & Service elements

1. Air
2. Compressor
3. Air Filter
4. Air Pressure Regulator
5. Air Lubricator
6. Air Service Unit
7. Pneumatic Silencer
 Air
The earth is surrounded by an envelope of air known as atmosphere.
The composition of this 12 mile thick envelope. Due to the
compressibility of air, increasing the pressure causes decrease in the
volume of air.

Boyles Law: - Boyle discovered that the pressure and the volume of
a particular quantity of gas was constant provided that the
temperature did not vary.
 PRESSURE MEASUREMENT

Atmospheric pressure = 1 Bar = 100Kpa = 100KNm2 = 14.5 PSI

F (Force, Newtons)
F
P =
A

A (Area, metres squared)

P (Pressure, Nm-2 )
 Compressors

A compressor is a machine that compresses air or another

type of gas from a low inlet pressure (usually atmospheric)
to a higher desired pressure level. This is accomplished by
reducing the volume of the gas. Air compressors are
generally positive displacement units and are either of the
reciprocating piston type or the rotary screw or rotary vane
types.
Graphic symbol
Types of compressor

•Piston Compressor
In this type of compressor a cylinder
bore encloses a moving piston. As the
crankshaft of the compressor rotate, the
piston moves within the cylinder,
similar to the piston in a car engine. As
the piston is pulled down, the volume
increases, creating a lower atmospheric
pressure in the piston chamber. This
difference in pressure causes air to
enter via the inlet valve. As the piston is
forced upwards the volume of air
reduces. The air pressure therefore
increases. Eventually the pressure
forces the outlet valve to open.
•Vane Compressor
The following figure shows a cutaway view of the sliding-vane-type
rotary compressor. The air inlet is placed where the volume of the
compression chamber is greatest, the outlet where the volume is
smallest. Consequently, as the vanes turn, the space between them is
reduced. This reduction in volume compresses the air as it travels from
the inlet to the outlet.
•Screw compressor
There is a current toward increased use of the rotary-type
compressor due to technological advances, which have produced
stronger materials and better manufacturing process. The
following figure shows a cutaway view of a single-stage screw
type compressor. Precise positioning of the screw is essential for
its performance. Oil provides a seal between the rotating screws
as well as lubricating the parts and cooling the air. The oil is
then separated from the air before it enters the system.
•Lobe compressor
In this type of compressor the rotors do not touch and
certain amount of slip exists. This slip increases as the
output pressure increases. It is therefore operated at
maximum speed for the highest efficiency. 17.3 bar is
obtainable with this type of constant displacement
compressor.

Inlet Outlet
 Compressor Specification

Input volume of Input volume of Output Output pressure

air in air in liter/min pressure in bar in pounds per
cubic foot/min square inch (PSI)

Input voltage Loudness of

in volt output sound in
decibel (DB)

Input frequency
in Hertz (Hz)
Input current
in Amp.
Output power in
Horse power (HP)
Rotating speed
of crankshaft in
Output power in revolution per
Kilowatt (KW) minute (rpm)
 Air Filter
The air needs to be filtered to be free of moisture and contamination.
Air filter is used to do this job. The filter elements remove the particles
and moisture as small as 5 microns. Normally 30-50 micron filter is
used in pneumatic system.

Graphic symbol
 Air pressure regulator
The pressure regulator is used to adjust the desired pressure for the
pneumatic system. This use a piston to sense downstream pressure
fluctuations. The piston, in turn, works against a set spring pressure.
As the pressure downstream drops it is sensed by the diaphragm and
the poppet valve opens. This adjusts the position of the poppet valve,
which limits the downstream pressure to the pre-set valve.

Graphic symbol
 Air lubricator
A lubricator ensures proper lubrication of internal moving parts
pneumatics components. The proportional increase in oil mist by an
increase of air flow is achieved by the spring loaded poppet assembly.
As the flow increases and the valve opens, the area is increased and a
pressure differential created.

Graphic symbol
 Air service unit
Filters, regulators and lubricators can be combined to ensure optimum
compressed air preparation for a specific pneumatic system.

Graphic symbol
 Pneumatic Silencer
To decrease the noise of air in the outlet of valves, a silencer can be
used. They are made from the porous plastic or bronze. Some of them
are equipped with a control flow valve to control velocity of flow in the
outlet of valves as well.

Graphic symbol
 2) SIGNAL ELEMENTS

Manually Operated

General manual Lever

Push button Pedal

Pull button Treadle

Push/pull button Rotary knob

 Mechanically Operated

Plunger Pressure

Spring normally Pilot pressure

as a return

Roller Differential pressure

Uni-direction or Detent in 3 positions

one way trip
Electrically Operated

Solenoid Solenoid pilot

direct with manual
override and
external pilot
Solenoid pilot supply

When no integral or
Solenoid pilot external pilot
with manual override supply is shown it
and integral pilot is assumed to be
supply integral
3) Direction Control Elements

 2/2 Direction control valve

 3/2 Direction control valve

 4/2 Direction control valve

 5/2 Direction control valve

 5/3 Direction control valve

Port & Position.mp4

 Basically a valve is named in the following order

1. No. of positions
2. No. of ports

1. No. of positions
No. of positions Graphic symbol

1 2
2 position

1 2 3
3 position
2. No. of ports Symbol
2 ports

3 ports

4 ports

5 ports
 GRAPHIC REPRESENTATION

Switching positions are shown Symbols for valve actuations

by squares and are drawn are shown at the left hand side
adjacent to each other Working ports or right hand side only

Line with arrow represents

direction of flow. Shut-off 4 2
position is shown by T.

5
1 3 The lines drawn on the outside
Normal position is the of the square in the normal or
switching position when the initial position represent the
valve is not actuated ports

Pressure Exhaust
ports ports
 2/2 DIRECTION CONTROL VALVE

Basic valves before Examples, push button operated

operators are added with spring return

Normal position

Function 2/2
 2/2 DIRECTION CONTROL VALVE

Basic valves before Examples, push button operated

operators are added with spring return

Operated position

Function 2/2
 3/2 DIRECTION CONTROL VALVE

Basic valves before Examples, push button operated

operators are added with spring return

Normal position

Function 3/2
 3/2 DIRECTION CONTROL VALVE

Basic valves before Examples, push button operated

operators are added with spring return

Operated position

Function 3/2
 4/2 DIRECTION CONTROL VALVE

Basic valves before Examples, push button operated

operators are added with spring return

Normal position

Function 4/2
 4/2 DIRECTION CONTROL VALVE

Basic valves before Examples, push button operated

operators are added with spring return

Operated position

Function 4/2
 5/2 DIRECTION CONTROL VALVE

Basic valves before Examples, push button operated

operators are added with spring return

Normal position

Function 5/2
 5/2 DIRECTION CONTROL VALVE

Basic valves before Examples, push button operated

operators are added with spring return

Operated position

Function 5/2
 5/3 DIRECTION CONTROL VALVE

 Three position valves have a normal central

position that is set by springs or with a manual
control such as a lever
 The flow pattern in the centre position varies
with the type. Three types will be considered
 1, All ports sealed

 2, Outlets to exhaust, supply sealed

 3, Supply to both outlets, exhausts sealed

 5/3 DIRECTION CONTROL VALVE
 All valves types shown in the normal position

 Type 1. All ports sealed

 Type 2. Outlets to exhaust

 Type 3. Supply to outlets

 5/3 DIRECTION CONTROL VALVE
 All valves types shown in the first operated position

 Type 1. All ports sealed

 Type 2. Outlets to exhaust

 Type 3. Supply to outlets

 5/3 DIRECTION CONTROL VALVE
 All valves types shown in the normal position

 Type 1. All ports sealed

 Type 2. Outlets to exhaust

 Type 3. Supply to outlets

 5/3 DIRECTION CONTROL VALVE
 All valves types shown in the second operated position

 Type 1. All ports sealed

 Type 2. Outlets to exhaust

 Type 3. Supply to outlets

 4) FINAL CONTROL ELEMENTS
(Flow control valve)
Throttle valve
Graphic symbol
Check valve or Non return valve

Graphic symbol
One way flow control valve

Graphic symbol
Quick exhaust Valve

Graphic symbol
Logic Valves
LOGIC “OR” SHUTTLE VALVE
Input Output
A B C
 The OR logic valve has two OFF OFF OFF
inputs and one output. ON OFF ON
OFF ON ON
 The output is ON if one or two ON ON ON
inputs are ON
C

 And the output is OFF only if

all outputs are OFF.

A B

C
Graphic symbol
C

A B
A B
LOGIC “AND” SHUTTLE VALVE

 The AND logic valve has two

inputs and one output. Input Output
A B C
 The output is ON only if all two OFF OFF OFF
inputs are ON ON OFF OFF
OFF ON OFF

 And the output is OFF if one or ON ON ON

more inputs are OFF.

C C

Graphic symbol
A B A B
C C
C C
A B A B
ISO 1219-1 Popular old
symbol symbol A B A B
5) WORKING ELEMENTS
How to actuate a single acting cylinder

Position 1 Position 2

3/2 way push button operated with spring return

How to actuate a single acting cylinder

Position 1 Position 2

3/2 way push button operated with spring return

How to actuate a double acting cylinder

Position 1 Position 2

5/2 way hand lever operated valve with spring return

How to actuate a double acting cylinder

Position 1 Position 2

5/2 way hand lever operated valve with spring return

Pneumatic Actuators

1. Pneumatic Cylinders
 Used for linear motion

2. Pneumatic Rotary Actuators

 Used for rotary motion

3. Pneumatic Semi-Rotary Actuators

 Used for linear & rotary motion
 Pneumatic Cylinders
The cylinders converts the energy of the compressed air into
linear motion which extend or retract the piston rod.

Graphic symbol
 Pneumatic Rotary Actuators
The rotary actuators converts the energy into a rotary motion.
Most of them is Vane air motor.

Graphic symbol
 Pneumatic Semi-Rotary Actuators
Limited rotary motion can be achieved by incorporating a rack
and pinion into a linear actuator or as seen opposite by a Vane
Mechanism within the body of the cylinder.

Graphic symbol
 Solenoid Valve
1. Apply Current
2. Magnetic Field Builds
3. Plunger Become Attracting Magnets
4. Magnetic Force Drives Plunger

Graphic symbol

Direct-Acting Solenoid Valve Animation.mp4

 Working principle of Solenoid Valve
When an electric current flow through a coil, a magnetic
field is generated

The following applies to the

strength of the magnetic field.

•Increasing the numbers of

windings increases the field.

•Increasing the strength of

the current increase the field.

•Lengthening the coil reduces

the field.
TYPES OF SOLENOIDS
1) Push 2) Pull 3) Clapper

4) Rotary 5) Open 6) Closed

 Comparison between Pneumatic, Electro
Pneumatic & PLC based control System
Parameter Pneumatic System Electro Pneumatic PLC Based Control
System System
Power medium Compressed air Compressed air Compressed air
Control Compressed air Electricity(AC/DC) Electricity(voltage or
medium current control)
Final control Pneumatically actuated Solenoid operated Solenoid operated
elements directional control valves directional control valve directional control valve
Using logic valves, time Using relays, timers, Using program elements
Signal
delay valves, pressure counters, pressure for logic, time-delay,
processing
sequence valves etc switches etc counting etc.,
Signal Permits energy flow in Inhibits energy flow in Scans for ‘1’ signal state
elements the normal position the normal position to allow power flow

On-delay & Off-delay On-delay and Off delay Program elements in on-
Timers pneumatic timers electrical/electronic delay, off-delay, and
(NO/NC type) timers other modes
Pneumatic latch (5/2-DC Electrical latch Setting and resetting
double-pilot valve) (Dominant ON and instructions with coils or
Memory
Dominant OFF circuits) boxes (set priority and
elements
and 5/2-DC double reset priority)
solenoid valve
Up-counter & down- Up-counter & down- Program elements in up-
Counters counter(pneumatic) counter(electrical) counting and down-
counting modes
Air pressure losses in pipelines
 General Malfunctions in pneumatic system
Disturbances Possible causes Rectification
Machine is working, but Upstream flow restriction or air •Fit larger pipe
is weakening in starvation •Install larger compressor
performance due to
Downstream flow restrictions •Check twisted tube/blocked silencers
slower operation
downstream and renew
Lack of lubrication •Lubricate machines
•Fit air line lubricator
Actuator is weakening Flow regulator set too low •Re-adjust flow regulator
in performance due to
Tube twisted •Re-new
slower operation
Piston rod bent •Repair or replace actuator
Barrel dented
Machine stop Failed pneumatic or electrical •Re-establish power supplies
supply
Faulty products due to Adjusting mechanism out of •Re-adjust mechanism
faulty machine alignment
adjustments or
Insufficient power to a •Increase pressure to the actuator or
misalignment of
stamping or pressing actuator replace the actuator with a large one
components
Leakage Loose joints, fittings or glands •Tighten loose joints, fittings or glands

Faulty or damaged fittings or •Replace or repair the defective part

ruptured pipes and hoses
 Malfunctions in Pneumatic Cylinders
Disturbances Possible causes Rectification
With valve (Double) cup packing is •Replace cup packing
connected, air leaking
escapes out of vent (Double) cup packing is •Tighten cup packing
hole loose (or valve is defective)
Air escapes to Cup packing is leaking •Replace cup packing
atmosphere at flange Cup packing is mounted in •Reverse cup packing
bushing the wrong way
Air escapes at piston Groove ring is defective •Fit a new grooving
End position cushion Lip seal on the cushioning •Fit a new lip seal
does not respond plunger leaks or has been
•Re-fit the lip seal
fitted the wrong way round
Single-acting Composition spring is •Fit a new spring
cylinder piston rod damaged
does not return to
the end position
Misalignment of Excessive jerks •Align piston/piston rod or
piston/piston rod or cylinder body
cylinder body Wrong operation •Set right the operation
 Malfunctions in Pneumatic Valves
Disturbances Possible causes
Valve leak •Dirt
•Broken seals
•Weak or broken spring
•Excessive wear
Valve operating •Line pressure too low
mechanism fails •Control plunger broken
•Groove ring defective
•Corrosive damage to
surfaces by condensate
Valve plunger does not •Look for broken spring
return back
Sluggishness of valves •Dirt collected in the valve
especially at the groove ring
Valve fails to pass the •Actuating means not
rated amount of air stroking properly
•Bent trip cam
•Worn tripping mechanism
Failure of solenoid coil •Coil loosely fixed to the
solenoid stem
•Coil vibrates
•Overheating of coils
•Mismatched coils and stem
Rectification
•Remove dirt
•Replace seals
•Replace spring
•Lubricate
•Set control pressure
•Replace plunger
•Replace defective part
•Use proper lubricant
•Replace defective part
•Clean the vent hole
•Set right alignment
•Straighten trip cam
•Replace defective part
•Fix coil firmly to solenoid stem
•Fix coil firmly
•Fix coil firmly
•Use matched coils and stem
 General Safety Measures

1. Keep your work place clean before and after work.

2. Use personal protective devices for all hazardous
jobs.
3. Follow the standard procedure while operating a
machine.
4. Know your job thoroughly
5. Inspect daily for damaged tubing, fittings & leaks
6. Check the interlock system at regular intervals
7. Repair or replace components that show signs of
wear or damage
8. Clean the spillage of grease, oil, etc., immediately
9. Never direct the compressed air towards yourself or
anyone else for cleaning
10. Never use the compressed air for cleaning away
chips and dust. Flying particles can be dangerous.
 Basics Pneumatic circuits

A pneumatic circuit is usually designed to

implement the desired logics. However, there
are several basics circuits, which can be
integrated into the final circuit.
Ex. 1) Air pilot control of double-acting cylinder

In single acting cylinder compressed air is applied on only one side of

the piston face. The other side is open to atmosphere. For return
movement of the piston spring is used. This actuator can produce
work in only one direction. Single acting cylinder with built in spring
the stroke length is limited due to natural length of spring. Single
acting cylinder are available in stroke length up to approximately
100mm. Due to construction and simplicity it is suitable for compact
short stroke.
Ex. 2) Air pilot control of double-acting cylinder

Directional control valve are giving path to an air stream. It controls

actuator. The directional control valve is characterized by its number
of controlled connection or ways and by the number of switching
position.
5/2 way D.C. valve has got 2 position and 5 ports i. e. 2 exhaust, 2
outputs & 1 input.
The 5/2 way valve is used primarily as a final control element for the
control of double acting cylinder.
Ex. 3) Air pilot control of double-acting cylinder

The 5/3 way valve has five ports and three position. In this valve
lines are closed in the middle position. This enables the piston rod of
cylinder to be stopped in any position over its range of stroke
although intermediate position of the piston rod cannot be located
accurately its symbol is as follows.