Mech Syst LO1 PDF

TECHNOLOGICAL STUDIES
Intermediate 2
Mechanical Systems
Section 1
Outcome 1 – Pneumatic Systems
DET Technological Studies Support Materials: 1

Applied Electronics (Int 2) Outcome 1
OUTCOME 1
Outcome 1 – Design, construct and evaluate pneumatic systems

When the students have completed this unit of work they should be able to:
• Interpret pneumatic system and circuit diagrams.
• Describe the operation of pneumatic systems
• Pipe up/construct pneumatic systems.
• Have an appreciation of safety requirements when operating pneumatic systems.
• Perform calculations to determine cylinder pressure, piston force and area.
• Evaluate pneumatic systems.

INTRODUCTION
Pneumatics is all about using compressed air to do work. Compressed air is simply
the air we breathe forced into a small space. Pneumatic systems are more common
than you would think and are used extensively in industry, for example to move
objects off a conveyor or hold/clamp parts of an assembly together. In fact,
pneumatics is used quite a lot every day.
CAR TYRE BUS DOORS
MOVING PARTS IN A PROCESS
MS.Int 2.O1 fig 1
You will all have used compressed air when you have blown up a football or the tyre
on a bicycle. To understand how pneumatics uses compressed air to do things we
simply need to think of blowing up a balloon. It takes a lot of air to fully inflate the
balloon and to stretch the balloon to its full size. If we inflate the balloon too much,
the air will force the balloon to burst. If you release the balloon, the air will begin to
escape and will propel the balloon around the room until all the air has escaped. All
of this happens because you have squashed or compressed a lot of air inside the
balloon and stored up energy.
MS.Int 2.O1 fig 2
Most pneumatic systems rely on a constant supply of compressed air to make them
work. This is provided by a compressor, which is an air pump driven by a motor or
engine. The compressor sucks in air and stores it in a tank called a receiver. This
compressed air is then supplied to the system through a series of pipes.

Health and Safety
Pneumatic devices and systems are safe, clean and reliable but we must learn to use
them properly to avoid accidents. When using pneumatic equipment, we must always
follow these safety rules:
1. Never blow compressed air at anyone, not even yourself.
2. Never let compressed air come into contact with your skin, as this can be very
dangerous.
3. Always wear safety goggles when you are connecting and operating circuits.
4. Check that all air lines are connected before turning on the main air supply.
5. Always turn off the main air supply before changing a circuit.
6. Keep your hands away from moving parts.

CYLINDERS
Pneumatic equipment can be split up into two basic categories of cylinders and
valves.
Cylinders are the ‘muscles’ of pneumatic systems as they are used to move, hold and
lift objects. They can even be used to operate other pneumatic components.
Cylinders are operated by compressed air and they covert the stored energy into linear
motion.
There are two types of cylinder that we will be using: a single acting cylinder and a
double acting cylinder.
Single Acting Cylinder

A single acting cylinder requires only one air supply. If we supply compressed air to
a single acting cylinder, the air pushes against a piston inside the cylinder and causes
it to outstroke. When the piston has fully outstroked it is said to be positive. If we
stop the supply of air then a spring inside the cylinder causes the piston to instroke to
its starting position and the piston is said to be negative. The symbol for a single
acting cylinder is shown below.
MS.Int 2.O1 fig 3
Single acting cylinders are used in situations where their simple design and small size
are an advantage. They produce small outstroke forces and their use is limited to
operations that only require use of the outstroke. This is because the spring produces
only enough force to instroke the piston.
Double Acting Cylinder

A double acting cylinder requires two air supplies, one to outstroke the piston and the
other to instroke the piston. Compressed air is applied to one side of the piston then
other to make it move positive and then negative. The symbol for a double acting
cylinder is shown below.
MS.Int 2.O1 fig 4
Double acting cylinders are used more often in pneumatic systems than single acting
cylinders. They are able to produce greater forces and we can take advantage of both
the outstroke and instroke forces to lift and move objects.

VALVES
Valves provide the necessary control of the compressed air being supplied to the
cylinder. They can turn the air on or off, change the direction that the air is flowing or
even slow down the airflow. The most common type of valve is the 3/2 valve.
3/2 Valve
A 3/2 valve is so called because it has 3 ports or connections and two states of
operation. The ports are always numbered in the same way.
Port 1 – main air supply connection

Port 2 – output connection to other components
Port 3 – exhaust
The valve has two states of operation. One state prevents air from being supplied to
other components and the other allows the air to flow freely.
State 1 – Off/Unactuated State

In this state, the main airflow through the valve is blocked and so air is unable to
reach other components such as cylinders. However, any air within the cylinder is
able to exhaust through the valve and this will allow the cylinder to return to its
original position. Study the symbol below and ensure that you understand how the air
flows through the valve.
1
2
3
MS.Int 2.O1 fig 5
State 2 – On/Actuated State

In this state, the main air supply is able to flow freely through the valve and supply
components such as cylinders with air. Study the symbol below and ensure that you
understand how the air flows through the valve.
1 2
3
MS.Int 2.O1 fig 6
The complete symbol for a 3/2 valve combines both states and is usually drawn in the
off or unactuated state. The complete symbol is shown below.
MS.Int 2.O1 fig 7

ACTUATORS
There are a number of different ways that we can change the state of the 3/2 valve.
The most common way is by using a push button. A push button is useful for quick
and easy starting of a sequence or as a safety circuit breaker. By pressing the button,
the valve changes to the actuated state and allows main air to flow through to other
components. If we release the button, a spring inside returns the valve to its off state.
The symbol for a push button, spring return 3/2 valve is shown below.
MS.Int 2.O1 fig 8
Below is a list of the most common types of actuators. They are always drawn onto
the standard symbol for the 3/2 valve.
PLUNGER ROLLER
TRIP
PUSH
BUTTON SOLENOID
LEVER PILOT AIR
ROLLER DIAPHRAGM
SPRING
MS.Int 2.O1 fig 9
Not all of these actuators are intended to be used by a human operator. For example,
an outstroking piston from a single or double acting cylinder actuates the roller trip.
The solenoid uses an electrical pulse to change the state of the valve and this allows
us to use combined electrical and pneumatic systems.

SIMPLE CIRCUITS
A bottling plant uses a single acting cylinder to press lids onto bottles. The cylinder is
controlled by a push button, spring return 3/2 valve. An operator presses the button
when the bottle is in the correct position.
MS.Int 2.O1 fig 10
The pneumatic circuit is shown below.
MS.Int 2.O1 fig 11
When the button is pressed, the valve changes state and supplies air to the single
acting cylinder. This causes the piston to outstroke with enough force to press the lid
onto the bottle. When the button is released, the valve returns to its original state and
the piston is able to instroke ready for the process to begin again.

Assignment 1
1. Build the circuit shown above for the bottling plant.
a. Press the button on the valve and keep it pressed. Explain what happens.
b. Release the button and explain what happens.
c. Using the correct terminology, explain how the circuit operates to seal the bottles
with the lids.

In a section of a recycling plant, metal cans are dipped in a chemical solution to
remove traces of dirt, oil and paint. A double acting cylinder is used to raise and
lower a basket containing the cans.
MS.Int 2.O1 fig 12
The pneumatic circuit is shown below.
Valve A Valve B
MS.Int 2.O1 fig 13
When the operator presses the button on valve A, air is supplied to the double acting
cylinder which outstrokes and lowers the basket into the chemical solution. When the
button on valve B is pressed, air is supplied to the other side of the piston which
instrokes and raises the basket. Any air in the cylinder at this time is able to exhaust
through port 3 of valve A.

Assignment 2
1. Build the circuit shown above for raising and lowering the basket.
a. Press the button on valve A to outstroke the cylinder. Does the piston instroke
when you release the button?
b. Press the button on valve B. What happens to the cylinder?
c. What happens when you press both buttons at the same time?
d. Leave both valves unactuated and try moving the piston. Why is it so easy to
move?
e. Using the correct terminology, explain how the circuit operates to raise and lower
the basket.

5/2 VALVES
The problem with controlling a double acting cylinder with two 3/2 valves is that
when neither valve is actuated, no air is being supplied to the cylinder to hold the
piston in place. Any air within the cylinder is able to exhaust through port 3 on each
valve. This means that any force or effort placed on the piston will make it move
easily. A further disadvantage is that the 3/2 valve needs to be actuated until the
double acting cylinder has fully outstroked or instroked. Releasing the valve before
the stroke is complete will result in the piston stopping short of its final position.
We have greater control over a double acting cylinder if we control its outstroke and
instroke using a 5/2 valve. This valve has 5 ports and two states of operation. The
ports are always numbered in the same way.
Port 1 – main air supply connection

Port 2 – output connection to cylinder
Port 3 – exhaust
Port 4 – output connection to cylinder
Port 5 – exhaust
The valve has two states of operation. One state supplies air to outstroke a double
acting cylinder and the other state will cause it to instroke.
State 1 - Instroke
In this state, the main air flows through the valve from port 1 to port 2. Any air within
the cylinder is able to exhaust through the valve from port 4 to port 5. In this state, a
5/2 valve will cause a double acting cylinder to instroke or hold the piston in the
negative position as air is always being supplied to the cylinder. Study the symbol
below and ensure that you understand how the air flows through the valve.
AIR FROM AIR TO

CYLINDER CYLINDER
4 2
5 3
1
MS.Int 2.O1 fig 14

State 2 – Outstroke
In this state, the main air flows through the valve from port 1 to port 4. Any air on the
other side of the piston is able to exhaust through the valve from port 2 to port 3. In
this state, a 5/2 valve will cause a double acting cylinder to outstroke and hold it in the
positive position. Study the symbol below and ensure that you understand how the
air flows through the valve.
AIR TO AIR FROM

CYLINDER CYLINDER
4 2
5 3
1
MS.Int 2.O1 fig 15
The complete symbol for a 5/2 valve is shown. The cylinder, main air and exhaust
lines are only ever drawn on one half of the symbol depending on which part is active
in the circuit. It is usual, however to draw the symbol in such a way as it would hold
a double acting cylinder in the negative position.
MS.Int 2.O1 fig 16
5/2 valves can be operated or actuated in the same way as 3/2 valves however, the
most common way of actuating a 5/2 valve is pilot air. A pilot air 5/2 valve will
change state when a brief air signal acts at either end of the valve. This signal is most
often supplied from a 3/2 valve. In the example shown below, the button on Valve A
only needs to be pressed momentarily in order to change the state of the 5/2 valve.
The 5/2 valve will supply the double acting cylinder with air in order for it to
outstroke.

Valve A
MS.Int 2.O1 fig 17
Notice that the pilot air lines to the 5/2 valve are drawn as broken or dashed lines to
distinguish them from the other air lines in the circuit.

Assignment 3
1. A hopper door is connected to the end of a double acting cylinder. Sand is fed
into the hopper from above and when the hopper is full, the door of the hopper
must open to allow the sand to fall through onto a wagon. The hopper door then
closes and the process is able to begin again.
Valve A Valve B
MS.Int 2.O1 fig 18
a. Build and test the circuit shown above for opening and closing the hopper door.
b. Does pressing Valve A or Valve B close the hopper door?
c. Using the correct terminology, explain how the circuit operates.

2. The door in a secured entry system is controlled by pneumatics. A simplified
circuit diagram is shown below with some of the piping missing.
A
SLIDER TRACK
CYLINDER B
CRANK
MS.Int 2 .O1 fig 19
a. Name each of the components A, B and C used in the pneumatic circuit shown
above.
b. Complete the missing piping in the circuit diagram.
c. Using appropriate terminology, describe how the systems works from when Valve
A is actuated.

3. A barrier to a company car park is controlled by a security guard. The guard
carefully checks all cars entering the premises. The barrier is to be raised and
lowered by a double acting cylinder.
MS.Int 2.O1 fig 20
a. Design a pneumatic system that will solve this problem using equipment that you
have available.
b. Pipe up and test your solution.
c. Produce a list of all the components used in your solution using their correct
names.
d. Using the correct terminology, describe how your solution raises and lowers the
barrier.
e. Why is a double acting cylinder used instead of a single acting cylinder in these
circumstances?

FLOW CONTROL VALVES
You will have noticed in all the circuits you have built so far, that the cylinders
operate very quickly. Sometimes this is exactly what we want but very often it would
be dangerous or impractical for the cylinder to work this fast. For example, think
back to the exercise where a basket was lowered into a chemical solution. If this
happened too fast then the chemical would splash out of the container. In this case,
we would want the cylinder to raise and lower the basket slowly.
We can slow down the airflow to a cylinder by using flow control valves. The most
common type is the unidirectional restrictor. This type of valve slows down the
airflow in one direction only. The symbol is shown below.
MS.Int 2.O1 fig 21
When air flows into the restrictor in the direction shown in figure 22, some of the air
takes the bypass route and forces the ball to seal the path. The air is then forced to
pass through the restriction and the flow is slowed down. We can alter the flow by
adjusting the small screw on the top of the restrictor.
RESTRICTION
AIR
FLOW
BYPASS
MS.Int 2.O1 fig 22
When air flows in the opposite direction into the restrictor, most of the air takes the
bypass route and forces the ball to open up the path. This allows the air to flow freely
and unrestricted.
AIR
FLOW
MS.Int 2.O1 fig 23
If we want to restrict the stroke of a cylinder, it is normal practice to restrict the

exhaust air coming from the cylinder rather than the main air being supplied to the
cylinder. This provides a much smoother motion in the piston.

Remember our example with the hopper door. It would be much more practical for
the door to open slowly, as this would allow the sand to fall more gently into the
wagon below. We would still want the door to close quickly so that the process could
begin again as soon as possible. Study the new circuit diagram below.
Valve A Valve B
MS.Int 2.O1 fig 24
To open the door of the hopper slowly, we need to control the speed of the instroke.
When Valve B is pressed, the pilot air 5/2 valve changes state and supplies the air to
instroke the double acting cylinder. However, air is trapped behind the piston and this
must escape or exhaust in order for the piston to move. The restrictor is connected in
such a way that the exhausting air must pass through the restriction. This slows down
the exhaust air and so slows down the speed that the cylinder can instroke.

Assignment 4
1. Build and test the pneumatic circuit shown above.
a. Using appropriate terminology, explain how the circuit works.

b. Explain why the exhaust air has been restricted in order to slow down the instroke.
2. For safety reasons, the entrance door to a storeroom in a warehouse must open and
close slowly. A double acting cylinder is used to slide the door. A simplified
circuit diagram is shown below.
MS.Int 2.O1 fig 25
Valve A Valve B
MS.Int 2.O1 fig 26
a. Build and test the pneumatic circuit shown above.

b. Explain why two restrictors are needed in this circuit.
c. Where would you place the push button, spring return 3/2 valves in relation to the
warehouse door?

Sometimes we might want to control the instroke and outstroke of a single acting
cylinder. We can control the instroke in the same way as a double acting cylinder, by
restricting the exhaust air. However, when a single acting cylinder outstrokes the
piston pushes against a spring and there is no exhaust air to control. In this case, we
use two ‘back to back’ restrictors. The spring prevents the jerky action of the piston
that occurs when this arrangement is used with a double acting cylinder.
A B
MS.Int 2.O1 fig 27
A simpler device for controlling the speed of the outstroke and instroke of a single
acting cylinder is a bi-directional restrictor. This restrictor has just one route for the
air and so the same rate of flow is achieved in both directions. A small screw on the
top of the restrictor adjusts the flow rate
Although this device is more economical than using two unidirectional restrictors, it
means that the instroke and outstroke speeds will be the same. If used with a double
acting cylinder then a jerky motion is produced rather than a smooth controlled one.
The symbol for a bi-directional restrictor is included in figure 28 below.
MS.Int 2.O1 fig 28

Assignment 5
1 a. In figure 27, which unidirectional restrictor controls the speed of the outstroke?
b. What is the purpose of the other restrictor in this circuit?
2. Describe some of the disadvantages of using a bi-directional restrictor to control

the speed of a double acting cylinder.
3. Part of a production line requires the company logo to be stamped on the

packaged goods. The content of the packages is fragile and so care must be taken
not to damage the boxes. It has been decided that a single acting cylinder is used
but it should outstroke slowly to avoid damaging the goods.
STAM P
BO X BO X BO X BO X
MS.Int 2.O1 fig 29
a. Design a pneumatic system that will perform this task.

b. Build and test your solution.
c. Name each of the components used.
d. Using the correct terminology, describe how the circuit operates.
4. As part of a drilling operation, the work piece requires to be held in a vice. The
vice is to be operated pneumatically by a double acting cylinder. To allow the
operator time to position the work piece, the vice must close slowly.
MS.Int 2.O1 fig 30
a. Design a pneumatic system that will perform this task.

c. Name each of the components used.
d. Using the correct terminology, describe how the circuit operates.
e. The weight of the vice means that a large force is required to open and close it. It
is suggested that two cylinders operating at the same time would be better. Using
a T-piece, alter your circuit so that two double acting cylinders operate at the same
time.

AND CONTROL
We can create basic control circuits using pneumatic equipment relatively easily. On
many production lines, operators become careless because they are so familiar with
the machine that they constantly use. One way to avoid accidents happening is to fit
the machine with a guard system, where the machine will only operate if the guard is
in position and the machine is switched on by the operator.
S LID IN G
DOOR
S TA RT/S TO P
VA LVE VA LVE
P O S ITIO N
MS.Int 2.O1 fig 31
This type of control can be achieved if we connect two 3/2 valves together in series.
Valve A Valve B
MS.Int 2.O1 fig 32
The single acting cylinder in this circuit will only outstroke if both 3/2 valves are
actuated at the same time. This is because Valve B is supplied with air coming from
Valve A. Pressing the button on Valve A supplies air to Valve B and if we press the
button on Valve B at the same time, this allows air to flow into the single acting
cylinder and cause it to outstroke.

We can summarise the behaviour of this type of circuit in a truth table.
VALVE A VALVE B CYLINDER
OFF OFF INSTROKE
ON OFF INSTROKE
OFF ON INSTROKE
ON ON OUTSTROKE
MS.Int 2.O1.fig 33

Assignment 6
1. A machine in a factory is very difficult to guard without affecting how the
machine carries out its task. The manager is very concerned that the operator
may have an accident as a result. In order to prevent this, the manager wants to
redesign the start/stop system of the machine so that the operator needs to press
two buttons before the single acting cylinder outstrokes.
MS.Int 2.O1 fig 34
a. Design a system that will only work if the operator is pressing two buttons at the
same time.
b. Build and test your system to check that it operates correctly.
c. Draw a truth table of your results.
d. Using appropriate terminology, describe how the system operates.
e. The manager thinks that the single acting cylinder operates too quickly. Alter
your design so that the cylinder outstrokes more slowly.
2. A single acting cylinder is used to bend metal brackets using a former attached to
the end of the piston rod. In order to operate safely, the system must satisfy the
following conditions:
• The cylinder must only outstroke if the guard is down.

• The process must only start if the operator presses both start buttons.
• The process can only begin when the metal is in the correct position and actuates a
3/2 valve.
a. Design a pneumatic circuit to carry out this operation.

b. Build and test your solution and ensure that it operates properly.
c. Using appropriate terminology, explain how your circuit controls the action of the
single acting cylinder.

OR CONTROL
In many industrial applications, pneumatic systems are controlled by either of two
operators. They may be working together on the same process or controlling a
process from two different positions. Quality control checks on production lines
usually involve two or more people. Damaged or unsatisfactory goods are rejected if
one or other person detects a fault and the goods are removed from the line by a single
acting cylinder.
MS.Int 2.O1 fig 35
This type of control requires two 3/2 valves to be connected together in parallel and
the use of an additional component called a shuttle valve.
Shuttle Valve
Valve A Valve B
MS.Int 2.O1 fig 36

A shuttle valve is a very simple device but it is essential to how an OR control circuit
works. If the button on Valve A is pressed, the ball in the shuttle valve is blown
across towards Valve B and air is directed towards the single acting cylinder. This
will outstroke the piston. If the button on Valve B is pressed, the ball is blown across
towards Valve A and air is directed towards the cylinder. This also causes the piston
to outstroke.
We can summarise the behaviour of this circuit in a truth table.
VALVE A VALVE B CYLINDER
OFF OFF INSTROKE
ON OFF OUTSTROKE
OFF ON OUTSTROKE
ON ON OUTSTROKE
MS.Int 2.O1 fig 37

Assignment 7
1. A window in a large factory is to be opened and closed by a single acting cylinder.
The cylinder is to be controlled by lever operated 3/2 valves, one placed at either
end of the factory floor as this provides the workers with nearby control. If either
of the two 3/2 valves is actuated, the cylinder should outstroke and open the
window.
MS.Int 2.O1 fig 38
a. Design a system that will work if a person at either end of the factory activates a
lever.
b. Build and test your system to check that it operates correctly.
c. Draw a truth table of your results.
d. Using appropriate terminology, describe how the system operates.
e. Someone suggests changing the shuttle valve to a T-piece. Explain why this is not
a good idea.
2. A pneumatic circuit has been devised for use in operating a sliding door to a
refrigerated store in a supermarket. For safety reasons, it must be possible for the
door to be opened or closed from both inside and outside the room. Additionally,
the door should open and close slowly.
MS.Int 2.O1 fig 39

A layout of the components to be used in the system is shown in figure 40.
CLOSE (OUTSIDE) OPEN (OUTSIDE)
CLOSE (INSIDE) OPEN (INSIDE)

MS.Int 2.O1 fig 40
a. Complete the circuit so that it operates properly.

b. Using appropriate terminology, explain how the circuit operates.
c. It is decided after a while that the door should open as quickly as possible but
continue to close slowly. Adjust your circuit to suit these new conditions.

3. A single acting cylinder is used to punch a hole in thin aluminium sheet. The
sheet forms part of a household accessory that the company manufactures. The
process can be controlled locally by an operator who must press two buttons at the
same time to outstroke the cylinder. The alternative is to control the process from
the control area directly above the production line. Both arrangements help to
prevent accidents during this potentially dangerous process. The pneumatic
circuit to carry out this process is shown.
Valve A Valve B Valve C
MS.Int 2.O1 fig
a. Build and test the pneumatic circuit shown above.

b. Draw a truth table of your results.
c. Using appropriate terminology, describe how the system operates.
d. When the process is controlled from the control area above the production line, it
is possible that someone working near the cylinder could still be injured, as the
machine is not guarded. Redesign the circuit to ensure that the single acting
cylinder will only outstroke if a guard is in position.
e. Explain the changes that you have made and how they improve the overall
performance of the circuit.

TIME DELAY CIRCUITS
Sometimes we require a time delay or pause in a circuit before something else
happens. Time delays are easily achieved with the use of two additional components
inserted into the system at the point where the delay is required. The components
required are a unidirectional restrictor (which we have already used) and a reservoir.
The arrangement is shown below.
Air
MS.Int 2.O1 fig 41
A reservoir is simply an empty container. When placed in a circuit it takes some time
to fill up with air and restore the working pressure of the circuit. The time it takes to
fill creates the pause or delay. We can change the length of the delay in two ways.
The first is to use a reservoir of a different size as large reservoirs take longer to fill.
The second way is to adjust the flow of air into the reservoir using a unidirectional
restrictor. We can slow down the airflow using the restrictor so that the air takes a
much longer time to fill the reservoir.
Time delay circuits can be useful in clamping or pressing applications where pressure
is applied by a cylinder for a set time. Such a circuit can be used to make plastic
containers. This type of pressing system makes use of a double acting cylinder to
press a hot plastic sheet into a mould. The plastic needs to be held in position for
several seconds to allow it to cool. The circuit for this system is shown in figure 42.

1
H O T P LAST IC
SH EET
1 3
1 2
5 4
1
3
2
1 4
2 1
MS.Int 2.O1 fig 42
When the push button, spring return 3/2 valve is pressed, the 5/2 valve changes state
and the cylinder containing the former outstrokes. When fully outstroked, the former
forces the plastic sheet into the mould and at the same time trips the roller. Although
this 3/2 valve has been actuated, the instroke is delayed because of the time delay.
The airflow to the reservoir is slowed and it takes several seconds for the reservoir to
fill. This allows the plastic container to cool before it is released when the piston
finally instrokes.

Assignment 8
1. Build and test the pneumatic circuit shown in figure 42.
a. Adjust the circuit to achieve a 2 second delay. Explain how to do this.

b. Explain the difference between piston speed control and a time delay.
c. Describe how the time delay could be increased to 10 seconds.
2. A machine is designed to test for wear and tear on drawer guides in a kitchen unit.
A double acting cylinder is used to constantly open and close the drawer and the
runners are checked regularly.
KITCHEN UNIT
PISTON MOVEMENT
B DRAWER DRAWER GUIDES
X
A
C
MS.Int 2.O1 fig 43
a. Build and test the pneumatic circuit shown in figure 43.

b. Name the components labelled A, B and C.
c. Describe how the circuit operates to complete one cycle of operation from the
position shown.
d. To allow the system to be stopped and checked, a 3/2 lever operated spring return
valve is inserted at point X in the circuit. Adjust the circuit to contain this valve.
Explain why this is an improvement to the original design.

3. A double acting cylinder is used to mark out even sections of fudge on a food
production line. It is important that the process runs continuously and that each
fudge bar is the same size. Pneumatics is used in many food production lines
because it is clean, safe and reliable to use. The circuit diagram is shown below.
MS.Int 2.O1 fig
a. Build and test the circuit shown above.

b. Adjust the restrictors so that the delay on each side is the same or as close as you
can make it.
c. This circuit is designed to run constantly but sometimes the machinery needs to be
cleaned. The only way to shut the process down is to shut down the main air
supply. Insert a 3/2 valve in the circuit that will allow the process to be stopped at
any time. Explain your choice of actuator for this valve.
d. Are there any other problems with this system that you think may affect the size of
the fudge bars?
e. Why is pneumatics a good choice for this type of production line?

AIR BLEED CIRCUITS
When designing pneumatic circuits it is often necessary to detect if something is in
place before the operation of the circuit continues, for example that a work piece to be
drilled is in the correct position. It is possible to use some actuators on 3/2 and 5/2
valves (such as a plunger or roller trip), to detect this but sometimes they interfere
with the set up of the system or are not sensitive enough. To overcome these
problems, we use what is known as an air bleed circuit.
The diagram below shows the junction between two conveyor systems in a factory.
Boxes are transferred from one conveyor to another by the action of a single acting
cylinder. The boxes are fairly light and an air bleed is used to detect when a box is in
the correct position ready for transfer.
SIN G LE AC TIN G
C YLIND ER
AIR BL EED
C O N VEYO R BELTS
MS.Int 2.O1 fig 44
The circuit used to achieve this is shown below.
MS.Int 2.O1 fig 45
Main air in the circuit is connected to a unidirectional restrictor in such a way as to

slow down the airflow. Air passes through the restrictor to a T piece, one end of
which has an unconnected pipe that allows the air to escape or bleed out into the
room. When the boxes block the air bleed, the pressure in the pipe increases and this
air provides a pilot air signal to the diaphragm valve. This actuates the 3/2 valve
which in turn outstrokes the cylinder and the box is moved from one belt to the other.
The single acting cylinder instrokes automatically ready for the process to begin
again.

Assignment 9
a. Explain what happens when the air bleed is blocked.

b. Why is an air bleed more useful for sensing when an object is in place than a
plunger operated 3/2 valve?
2. A paper mill uses a large guillotine controlled by a double acting cylinder to cut
the reams of paper to size. An air bleed is used to detect when the paper is in
position ready to be cut.
MS.Int 2.O1 fig 46
The pneumatic circuit to solve this problem is shown below.
MS.Int 2.O1 fig 47

b. What is the purpose of the roller trip, spring return 3/2 valve? What would you
expect to activate this valve?
c. It is discovered that the roller trip isn’t always actuated and needs to be reset
manually by an operator. It is very dangerous for the workers to be so close to the
guillotine blade and so it is decided to change the roller trip to an air bleed.
Redesign the circuit to take account of this.

3. A double acting cylinder is used to form hot acrylic sheet into the shape of soap
dishes. The process is started by an operator pressing a button which causes the
double acting cylinder to outstroke. It is important that the plastic is pushed fully
into the mould before the cylinder instrokes. To ensure this, two air bleeds are
used to ‘sense’ that the soap dish has been fully formed.
MS.Int 2.O1 fig 47a
a. Design a pneumatic circuit that will carry out this operation.

b. Build and test your solution to ensure that it operates correctly.
c. Using the correct terminology, describe how your circuit operates.
d. Explain why air bleeds are a good choice for detecting that the dish has been
formed correctly. Can you suggest another way of achieving this?
e. A further improvement to the system is that it should only operate when the
acrylic sheet is in the correct position, otherwise some of the dishes are not formed
properly. Redesign the circuit taking this into account.

4. An automatic door is designed so that, when the door is opened there is a time
delay before it automatically closes again. An air bleed is used to detect when a
person is approaching the door as the piping can be easily hidden under the
entrance mat. The pneumatic circuit is shown below.
MS.Int 2.O1 fig 47b
a. Build and test this circuit and ensure that it operates properly.
b. Study the circuit diagram carefully and explain what is controlling the instroke of
the cylinder.
c. Using appropriate terminology, explain how the circuit operates.
d. Alter the circuit so that the door closes slowly.
e. Describe any problems that may be encountered if this system was to be used at
the entrance of, say, a hospital.

SEMI-AUTOMATIC CIRCUITS
In a semi-automatic circuit, either the instroke or outstroke of the piston is automatic.
The most commonly used semi-automatic circuits involve an operator starting the
circuit and when the piston is fully outstroked, it actuates a valve that controls the
instroke. We have come across examples of semi-automatic circuits in the course
already.
On some production lines, drilling operations are started by an operator who is able to
ensure that the component to be machined is in the correct position. When the hole
has been drilled to the correct depth, a roller trip is activated which automatically
instrokes the cylinder.
D EPT H S TO P
R O LLE R T RIP
D RILL
W O R K PIECE
MS.Int 2.O1 fig 48
The pneumatic circuit that controls this operation is shown below.
Valve A
MS.Int 2.O1 fig 49

The operator starts the operation by pressing the push button. This changes the state
of the 5/2 valve and the cylinder outstrokes. The cylinder pushes the drill into the
work piece and when the correct depth has been reached, the roller trip is activated.
This changes the state of the 5/2 valve and the cylinder instrokes. The process is
ready to begin again.

Assignment 10
a. Why is this type of circuit described as semi-automatic?

b. The drill is inserted into the work piece too quickly for the hole to be drilled
properly. Alter the circuit so that the outstroke is slower.
2. A guard on a plastic forming machine is held in position by a double acting

cylinder. The guard is raised to allow the worker to remove the component and
insert a blank. The guard is raised on the push of a button but lowers
automatically.
G UIDE S
TR AV E L O F D O O R
MS.Int 2.O1 fig 50
a. Design a semi-automatic circuit that will automatically lower the guard by

outstroking the piston.
b. The operator complains that the guard raises and returns too quickly and he
doesn’t have enough time to remove the component. Someone suggests slowing
down the outstroke while another designer thinks that a time delay circuit would
be better. How would you improve the circuit? Explain your decision.
c. Rebuild the improved circuit and test it.
d. Using appropriate terminology, explain how the circuit operates.

3. Quality control on a production line is very important to ensure that all products
are made to the correct standard. A quality control officer can randomly select
goods on the line to be checked. He does this be pressing a button which activates
a double acting cylinder which pushes the object off the line. However,
sometimes the goods can become jammed and the piston should automatically
instroke. A circuit is shown below.
VALVE B
VALVE A
MS.Int 2.O1 fig 50a

b. Explain the purpose of Valves A and B.
c. Why is this described as a semi-automatic circuit?

AUTOMATIC CIRCUITS
Automatic circuits can perform tasks over and over again without the need of input
from an operator. These circuits make use of actuators such as a roller trip and
plunger to sense the position of the piston. We have come across an automatic circuit
already in the course.
Automatic control circuits are used in applications that require reciprocating motion
of the piston. For example, a production line requires the finished products to be
directed towards two loading bays ready for shipping out to customers. A double
acting cylinder controls the movement of a chute so that every second container is
sent to each bay.
MS.Int 2.O1 fig 51
The pneumatic circuit that controls this operation is shown below. Notice that roller
trip, spring return 3/2 valves are used to detect when the piston is positive and
negative.
Valve A Valve B
Y X
MS.Int 2.O1 fig 52
As the piston instrokes, it trips Valve A and the 5/2 valve changes state and the piston
is sent positive. When it is fully outstroked, it trips Valve B and the 5/2 valve returns
to its original position allowing the piston to instroke. The process begins all over
again and continues to operate.

Assignment 11
a. Sometimes the containers get trapped or jammed in the system and it needs to be
switched off. How do you get the circuit to stop? Is this an acceptable way of
controlling the circuit?
b. Someone suggests placing a lever operated 3/2 valve in the circuit at position X
but another worker disagrees and believes it should be point Y. Try both positions
and explain how these changes affect the operation of the circuit.
c. Why must a lever operated 3/2 valve be used instead of a push button?
2. A polishing machine requires reciprocating motion of a double acting cylinder.

So that the polished work piece can be removed, a valve is required to stop the
operation of the complete circuit. Experience of this type of process shows that if
the piston operates too quickly, the brush becomes hot and sticks to the surface of
the material.
MS.Int 2.O1 fig 53
a. Design a pneumatic circuit that will carry out this operation.

b. Build and test your solution and ensure that it fully solves the problem.
c. Using appropriate terminology, explain how you circuit works.
d. Why do we describe this type of circuit as automatic?

SEQUENTIAL CIRCUITS
Many pneumatic systems and machines are designed to perform a range of tasks in a
certain order or sequence. This usually involves the use of two or more cylinders
working together to complete the task.
For example, a company has automated its production line that involves metal blocks
being placed in a furnace for heat treatment. One cylinder is used to open the furnace
door and another pushes the metal blocks into the furnace.
MS.Int 2.O1 fig 54
The sequence of operations for this process is:
a. An operator pushes a button to start the process.

b. The furnace door is opened.
c. The block is pushed into the furnace and the piston retracts.
d. The furnace door is closed.
e. The sequence stops.
For this system to work successfully, we need to fully understand the order and
movement of cylinders A and B.
Stage 1
Cylinder A instrokes to raise the furnace door.
Stage 2
Cylinder B outstrokes and pushes the metal block into the furnace.
Stage 3
Cylinder B instrokes.
Stage 4
Cylinder A outstrokes and closes the furnace door.

The pneumatic circuit that carries out this operation is shown below.
CYLINDER A
VALVE G
VALVE H VALVE B
VALVE C
VALVE A
VALVE F
CYLINDER B
VALVE E
VALVE I
VALVE D
MS.Int 2.O1 fig 55

The system begins by actuating Valve A. This changes the state of Valve B and
causes Cylinder A to instroke, raising the door. When fully instroked or negative, the
piston trips Valve C and this sends a signal to Valve D. This 5/2 valve changes state
and sends Cylinder B positive. When fully outstroked, the piston trips Valve E and
the cylinder instrokes. When negative, Valve F is actuated and causes Cylinder A to
outstroke and stay in the positive position. The system stops and waits for a signal
from Valve A.
We can summarise the sequence of this circuit as follows:

Start, A-, B+, B-, A+, Stop

Assignment 12
1. Build and test the pneumatic circuit in figure 55.
a. Name the components labelled Valve D, Valve F and Valve H.

b. If Valve H was removed from the circuit, explain the effect this would have on the
operation of the furnace door.
c. Using appropriate terminology, explain how the circuit operates from when Valve
A is pressed.
d. A short delay is required before Cylinder B goes positive. Alter your circuit to
take this into account.
2. A company has automated a small section of its production line. The system
involves a component being pushed into position by a cylinder, drilled and then
released ready to begin again. The system involves two cylinders working
together in sequence: A+, B+, A-, B-. The system is automatic and should
continue to work through the sequence. However, a start/stop button should be
incorporated that would allow the system to be shut down in the event of a jam or
the drill bit breaking.
C YLIND ER B
D RILL C YLIND ER A
G U IDE S
MS.Int 2.O1 fig 56
a. Design a pneumatic system that would carry out this sequence of operations.
c. Using appropriate terminology, describe how it completes one sequence.
d. Explain your choice of actuators that sense the fully instroked and outstroked
positions of the two pistons.

3. Engraving is an operation that requires great skill and is very time consuming. In
an attempt to speed up the process, two double acting cylinders are needed to
work together in sequence to position the component and hold it in place. Cylinder
A pushes the component to be engraved into position. The clamping process is
achieved by connecting a parallel linkage system to the end of cylinder B. When
the cylinder instrokes, the linkage closes around the component to hold it steady.
The complete sequence required is A+, B-, A-, B+.
a. Design a pneumatic circuit to carry out this sequence.

b. Build and test the circuit and ensure that it operates correctly.
c. It is felt that the clamping operation works too quickly and sometimes the
component is moved out of line. Alter your circuit so that cylinder B instrokes
more slowly.
d. Not enough time is allowed for the engraving operation to take place before the
component is released. A short delay is needed in the circuit. Using the correct
components, position the delay where you think it would be most effective.
Explain your reasons for inserting it there.

INTERFACING AND ELECTRONIC CONTROL
Electronic Control
Although pneumatic circuits have many advantages, they can become complicated
and expensive when lots of components are needed. They can also be difficult to set
up and control. One possible way of overcoming these problems is to use electronics
or a computer interface to control the operation of pneumatic circuits. The advantage
of this is that electronic signals can be transmitted over much greater distances than
pneumatic signals. However, the main advantage is that electronic signals respond
faster than pneumatic signals and use less energy.
To control a pneumatic system electronically, we require the use of a solenoid

operated 3/2 valve. This valve is actuated when an electric current energises the coil
of the solenoid. If we can control the current flowing to the coil, then we can control
the operation of the entire circuit. This can be achieved easily by connecting switches
or sensors in series with the solenoid.
For example, a ten-pin bowling complex uses double acting cylinders to set up the
skittles once they have been knocked down. The cylinder is controlled by an electric
switch arrangement which energises solenoid operated 3/2 valves.
MS.Int 2.O1 fig 57
The circuit diagram is shown below.
12V dc 12V dc
C
B
MS.Int 2.O1 fig 58

Assignment 13
1. Build and test the electrical and pneumatic circuit shown in figure 58.
a. What advantages are there of controlling pneumatic circuits electronically?

b. If only pneumatic components were available, redesign the circuit so that it would
carry out the same operation.
2. A waste disposal system makes use of a hopper and container. The container
moves forward under the hopper, which tips up to empty its contents. Limit
switches are used to detect if the container is in place and if the hopper has been
tipped up properly. The system needs a start/stop button that will allow overall
control of the circuit.
a. Design an electronic and pneumatic system to fully solve this problem.

b. Using appropriate terminology, explain how the circuit operates.
c. Give examples of other ‘sensors’ that could be used to detect if the container and
hopper are in the correct place.
d. It is discovered that once the hopper has tipped right over, the double acting
cylinder begins to instroke before all the contents have emptied out. Insert a time
delay into the circuit that will overcome this.

Reprogrammable Interfacing
Most industrial pneumatic systems include a number of cylinders working together in
sequence. Certain sequences of operation are difficult to control using the equipment
we have come across so far. The circuits also become expensive to build and are
difficult to set up. However, we can overcome these problems by using a computer
interface to control complex tasks.
For example, a post office sorting system is used to separate three different sizes of
packages. The packages are carried on a conveyor belt to the first sort. At this point,
a single acting cylinder removes the largest packages, which are detected by use of a
switch. At the second stage, the medium packages are separated from the smaller size
ones, which continue to the end of the conveyor. As the content of the packages is
unknown, they should be removed carefully from the conveyor. For safety reasons,
the system should not operate unless the guard around the conveyor is in position.
MS.Int 2.O1 fig 60

The operation of this circuit can be summarised in a flow chart.
START
IS NO
GUARD
DOWN?
YES
IS
PACKAGE YES
LARGE?
EJECT
NO PACKAGE
IS
PACKAGE YES
MEDIUM?
EJECT
NO PACKAGE
MS.Int 2.O1 fig 61

Assignment 14
1a. Write a program that will control the operation of this circuit.
b. Build the necessary pneumatic and electronic system and connect it to your
interface. Test that your circuit operates properly.
c. It is suggested that there should be a start/stop button to halt the system in case of
a jam. Make the necessary adjustments to your program and circuit to
accommodate this.

2. A system is designed to control a chemical process. A cylinder moves a container
over the tank containing the chemical solution. Another cylinder lowers the
container into the tank. The chemical reaction takes several seconds to complete.
The cylinder lifts the container and it returns to its original position to be
unloaded.
CYLINDER B
CYLINDER A
TANK
MS.Int 2.O1 fig 62
a. Write a program that will control this operation.

b. Build the necessary pneumatic and electronic system and connect it to your
interface. Test that the circuit operates properly.
c. Investigate the reasons why this circuit would be very difficult to control using
pneumatic equipment only.

3. Packets of sweets in a factory are boxed automatically. The packets pass along a
conveyor belt and drop into the boxes. Each box should contain 12 packets only.
When full, the box is pushed onto another conveyor by a double acting cylinder
and taken away to be labelled and dispatched. A single acting cylinder pushes an
empty box into position ready for the process to begin again.
a. Draw a flow chart that clearly shows this operation.

b. From your flow chart write a computer program that will control the counting
sequence and the operation of the cylinders.
c. Build and test your solution and ensure that it works properly.
d. Describe what would happen if no empty box was in place to collect the sweets.
How could you overcome this problem?
e. Describe any necessary safety precautions that would need to be in place for this
system to work safely. Have you included these in your design?

FORCES IN A SINGLE ACTING CYLINDER
When a single acting cylinder outstrokes it produces a force. We can use this force to
lift objects or push them around. The size of the force produced by the cylinder as it
outstrokes depends on two things - the air pressure supplied to the cylinder and the
surface area of the piston. This means that we can increase the force by either
increasing the air pressure or increasing the size of the piston. However, systems and
components are designed to operate at specific pressure levels and we should never
increase the pressure beyond these levels.
The force produced by the cylinder as it instrokes is not affected by either of these
things. The instroking force is controlled by the return spring.
Pressure
Air pressure is measured in bar or in N/mm2. We can measure the pressure in a
pneumatic system using a pressure gauge. A gauge will always be connected to the
compressor but other gauges may be distributed throughout large systems to monitor
the pressure. This helps to detect leaks, as the pressure in the system would begin to
fall if air was escaping from the pipes.
Whenever we use pressure in calculations we require the units to be in N/mm2. This

often means converting from bar to N/mm2. This conversion is easy as you simply
divide the value in bar by 10. For example, if the pressure supplied to a system is 5
bar, we can find the equivalent value in N/mm2 by simply dividing 5 by 10.
Therefore, the value would be 0.5 N/mm2.
The chart below provides a quick reference.

bar 0 1 2 3 4 5 6 7 8 9 10
2
N/m m 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
MS.Int 2.O1 fig 63
Area
The surface area of the piston is the area that the air pushes against to outstroke the
piston. This area is circular or round.
MS.Int 2.O1 fig 64

The surface area is calculated using the formula:
d2
Area = πr = π 2
4
Force
The force produced as a single acting cylinder outstrokes is calculated using the
formula:
Force = Pr essure × Area
where force is measured in Newtons (N); pressure is measured in N/mm2 and area is
measured in mm2.
Worked example:
Air is supplied to a single acting cylinder at a pressure of 4 N/mm2. The diameter of
the piston is 25 mm. Calculate the force produced as the piston outstrokes.
Pressure = 4 N/mm2
d2 252
Area = π = 3.14 × = 491mm 2
4 4
Force = Pr essure × Area = 4 × 491 = 1964 N
Force = 1.96 kN

Assignment 15
1. What force is produced by a piston with a diameter of 20 mm supplied with air at
a pressure of 0.3 N/mm2?
2. What force will be produced by a 20 mm diameter cylinder as it goes positive

using a pressure of 0.8 N/mm2?
3. Calculate the outstroke force produced by a 40 mm diameter cylinder when it

operates with a supply pressure of 3 bar.
4. A stamping machine exerts a force of 454 N with a piston diameter of 34 mm.

Calculate the air pressure required for this operation.
5. A machine that places tops on bottles uses a single acting cylinder. The process
requires a force of 650 N. What air pressure needs to be supplied to the cylinder
with a diameter of 56 mm?
6. A force of 540 N is needed to push a packing case off a conveyor belt. The single
acting cylinder used has a diameter of 60 mm. What air pressure should be
supplied to the system?
7. A force of 500 N is needed to open a sliding door. The single acting cylinder
available has a piston diameter of 50 mm. What air pressure should be supplied?
8. A single acting cylinder is used to lift parcels onto a conveyor. This requies a
force of 180 N with the system operating at a pressure of 6 bar. Calculate the area
of the piston required.
9. A door requires a force of 400 N to slide it open. A single acting cylinder

supplied with a pressure of 5 bar controls the operation. Calculate the diameter of
the piston required to produce this force.
10. A furnace door weighs 100 N and is lifted by a single acting cylinder as it
outstrokes. Compressed air is supplied at a pressure of 4 bar. Calculate the
diameter of piston required to raise the door.

FORCES IN A DOUBLE ACTING CYLINDER
We already know that a double acting cylinder can be much more useful to us in
pneumatics because both the outstroke and instroke are controlled by compressed air.
This allows us to make use of the outstroke force and the instroke force. What we
learn however, is that the outstroke force is greater than the instroke force. Why is
this the case?
During the outstroke, the compressed air pushes against the surface area of the piston
in the same way as the single acting cylinder.
MS.Int 2.O1 fig 65
However, during the instroke the surface area is reduced because of the piston rod.
This means that the compressed air does not have as big an area to push against and so
it does not produce as big a force.
MS.Int 2.O1 fig 66
We can find this surface area or effective area as it is known, by calculating the area
of the piston rod and subtracting it from the surface area of the piston.

Worked example:
A double acting cylinder has a piston with a diameter of 25 mm. The piston rod is 5
mm in diameter. Pressure is supplied to the system at 4 N/mm2. Calculate the force
produced by the cylinder as it outstrokes and instrokes.
a. Outstroke force
Pressure = 4 N/mm2
d2 252
Area = π = 3.14 × = 491mm 2
4 4
Force = Pr essure × Area = 4 × 491 = 1964 N
Outstroke force = 1.96 kN
b. Instroke force
Pressure = 4 N/mm2
Effective area = Piston area – Piston rod area
d2 252
Pistonarea = π = 3.14 × = 491mm 2
4 4
d2 52
Pistonroda rea = π = 3.14 × = 20mm 2
4 4
Effective area = Piston area – Piston rod area = 491 – 20 = 471 mm2
Force = Pr essure × Effectivearea = 4 × 471 = 1884 N
Outstroke force = 1.88 kN

Assignment 16
1. Explain why the forces produced by a double acting cylinder on the outstroke and
instroke are different.
2. A double acting cylinder has a piston diameter of 20 mm and is supplied with air
at a pressure of 0.3 N/mm2. What force is produced as the piston outstrokes?
1. The piston rod has a diameter of 6 mm. What force is produced on the instroke?
2. A double acting cylinder is used to raise and lower a barrier in a car park. The air
pressure is 0.4 N/mm2 and the piston has a diameter of 40 mm. The piston rod is
12 mm in diameter. What forces are produced when the piston outstrokes and
instrokes?
3. A double acting cylinder produces a force of 0.4 kN. The effective area of the
piston is 0.04 m2. What pressure should be supplied to the cylinder?

Assignment 17
1. Give three examples of the everyday use of compressed air.
2. What device is used to supply pneumatic systems with compressed air?
3. Give two reasons why pneumatic systems are used in industry.
4. List the safety rules that we must observe when using pneumatic equipment.
5. Draw the symbol for the following pneumatic components:

a. single acting cylinder
b. double acting cylinder
c. unidirectional restrictor
d. bidirectional restrictor
e. shuttle valve
f. reservoir
g. push button, spring return 3/2 valve
h. pilot air operated 5/2 valve
6. Name the actuators shown below.
MS.Int 2.O1 fig 67
7. Why are double acting cylinders used more often than single acting cylinders in
industrial applications?
8. Explain the reasons why a 5/2 valve is better for controlling a double acting
cylinder than a 3/2 valve.
9. Explain, with the use of diagrams, how a unidirectional restrictor controls airflow
in one direction but not the other.

10. How do we control the speed of the outstroke of a double acting cylinder? Why
is it done this way?
11. Describe some of the functions that valves carry out in circuits.
12. Explain how a pneumatic AND circuit works and give one practical example of
its use.
13. Explain how a shuttle valve works.
14. Which two components are used together to create a time delay? Explain how
the components achieve the delay.
15. What is an air bleed and explain how it is used in pneumatic circuits.
16. Packages in a sorting system push against a plunger operated, spring return 3/2
valve. This triggers a single acting cylinder that ejects the package from the line.
However, some packages are too light and don’t always operate the plunger.
Describe, with the use of diagrams, an alternative method of controlling the
single acting cylinder.
17. Describe the difference between semi-automatic and automatic circuits.
18. What type of motion does an automatic circuit produce?
19. What is a sequential circuit?
20. What advantages are there in controlling pneumatic circuits with electronics?
21. In the formula Force = Pressure x Area, area is measured in mm2. What units do
we use to measure pressure and force?
22. What are gauges used for in pneumatic circuits?
23. Explain why the force produced by the instroke of a double acting cylinder is less
than the outstroke.
24. Explain how we might increase the size of force produced by a double acting
cylinder.
25. Find out the typical working pressures of a car tyre and bicycle tyre. Give the
values in both bar and N/mm2.


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TECHNOLOGICAL STUDIES

Outcome 1 – Pneumatic Systems

DET Technological Studies Support Materials: 1

Outcome 1 – Design, construct and evaluate pneumatic systems

DET Technological Studies Support Materials: 3

CAR TYRE BUS DOORS

MOVING PARTS IN A PROCESS

MS.Int 2.O1 fig 1

MS.Int 2.O1 fig 2

DET Technological Studies Support Materials: 4

1. Never blow compressed air at anyone, not even yourself.

6. Keep your hands away from moving parts.

DET Technological Studies Support Materials: 5

Single Acting Cylinder

MS.Int 2.O1 fig 3

Double Acting Cylinder

MS.Int 2.O1 fig 4

DET Technological Studies Support Materials: 6

Port 1 – main air supply connection

State 1 – Off/Unactuated State

State 2 – On/Actuated State

MS.Int 2.O1 fig 7

DET Technological Studies Support Materials: 7

MS.Int 2.O1 fig 8

LEVER PILOT AIR

MS.Int 2.O1 fig 9

DET Technological Studies Support Materials: 8

MS.Int 2.O1 fig 10

The pneumatic circuit is shown below.

MS.Int 2.O1 fig 11

DET Technological Studies Support Materials: 9

DET Technological Studies Support Materials: 10

MS.Int 2.O1 fig 12

The pneumatic circuit is shown below.

MS.Int 2.O1 fig 13

DET Technological Studies Support Materials: 11

DET Technological Studies Support Materials: 12

Port 1 – main air supply connection

AIR FROM AIR TO

DET Technological Studies Support Materials: 13

AIR TO AIR FROM

MS.Int 2.O1 fig 16

DET Technological Studies Support Materials: 14

MS.Int 2.O1 fig 17

DET Technological Studies Support Materials: 15

MS.Int 2.O1 fig 18

DET Technological Studies Support Materials: 16

MS.Int 2 .O1 fig 19

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MS.Int 2.O1 fig 20

DET Technological Studies Support Materials: 18

MS.Int 2.O1 fig 21

MS.Int 2.O1 fig 23

If we want to restrict the stroke of a cylinder, it is normal practice to restrict the

DET Technological Studies Support Materials: 19

MS.Int 2.O1 fig 24

DET Technological Studies Support Materials: 20

a. Using appropriate terminology, explain how the circuit works.

MS.Int 2.O1 fig 25

a. Build and test the pneumatic circuit shown above.

DET Technological Studies Support Materials: 21

MS.Int 2.O1 fig 28

DET Technological Studies Support Materials: 22