Fluid Automation - Unit 3 - White

Mechatronic Engineering: Fluid Automation
Unit 3 – Pneumatic actuators

PNEUMATIC SYSTEMS: PNEUMATIC CIRCUIT COMPONENTS
PNEUMATIC ACTUATORS
Pneumatic actuators: the components that carry out mechanical
work. This work is performed by means of the linear or rotary
movement of an appropriate element.
Pneumatic cylinders: linear movement or rotation of limited extent;
suitable for performing reciprocating movements.
Classification: Use the energy in compressed

• Single-acting cylinders air, converting it into
• Double-acting cylinders mechanical work over a limited
• Specialized cylinders stroke.
• Rotary cylinders
• Pneumatic motors. Capable of performing continuous

rotations.
SINGLE-ACTING CYLINDERS
Single-acting cylinders.
The moving part is a piston connected to a rod.
The piston slides inside a cylindrical barrel.
The air acts on only one side of the piston face.
A spring is incorporated in one of the cylinder chambers and
produces a specified thrust force.
5 (1) Barrel.
2 3
(2) Rear head.
(3) Front head (crossed by
the rod).
(4) Piston.
(5) Seal.
1 4 6 (6) Guide bearing.
Single-acting cylinders.
Advantages: use simpler control valves.
Disadvantages: limited work stroke, loss of part of the effective
thrust.
Push cylinder Pull cylinder

Graphic symbols of pneumatic components
Single acting cylinder
Double acting cylinder

with cushioning

with adjustable cushioning
DOUBLE-ACTING CYLINDERS
Can carry out work in both the extension and retraction strokes.
When the rear chamber (7) is supplied with compressed air and the
front chamber (8) is exhausted, the piston is extended. When the
sequence is reversed, the piston is retracted.
They are more widely used than single-acting cylinders, and can
perform longer strokes.
INLET FLOW OULET FLOW
8

DOUBLE-ACTING CYLINDERS
END STROKE CUSHIONING

Cushion rings: light duty applications. Not for high speeds and loads
Cushion ring
END STROKE CUSHIONING
Pneumatic cushioning: the piston features two shaped sleeves
with specially designed seals.
Adjustable screw Shaped sleeves

Guide bearing
Piston seals
Rod seal
Cushion seals
PNEUMATIC CUSHIONING
Pneumatic cushion permits to avoid the impact of the piston against
the fixed heads of the cylinder. The velocity of the piston is lowered
when the cylinder is next to reach the end of the stroke.
An air cushion permits the velocity to be lowered in a soft way
without mechanical impact, vibration and noise.
Below the piston is far from the end of the stroke. The compressed
air in the front chamber is exhausted directly through the main
passage and the exhaust port.
Main flow passage
V
PNEUMATIC CUSHIONING
When the piston is next to reach the end of the stroke the piston-sleeve
engages inside the main hole of the fixed head. The sealing element S
closes the main passage through the main hole. The air trapped between
the piston and the fixed head is released through a restricted area (by-pass),
rather than directly through the exhaust port. An adjustable needle valve
permits the restricted area to be regulated.
The air in this chamber is compressed (trapped) and slows piston movement.
Cushion seals Main flow passage (closed)

SEALS
Static seals: between non-moving parts
Dynamic seals: between parts in relative motion.
Static: between cylinder
barrel and caps
Dynamic: between piston and

barrel, between rod and bearing
cap
DYNAMIC SEALS
Lip seals: widely used for dynamic sealing on pistons and rods.
Chamber 2 Chamber 1 P1>P2

The sealing
unidirectional sealing
action occur
Single installation:
P1<P2
The sealing action
is not performed
The sealing force is radial, and is augmented by the pressure in the

chamber to be isolated.
DYNAMIC SEALS
CYLINDER MOUNTING
Cylinder mounting
depends on
movement kinematics
and how the load is
applied.
CYLINDER MOUNTING
Possible rod
connections.
Cylinder mounting
arrangements.
CYLINDER MOUNTING
Cylinder mounting arrangements.

CYLINDER SELECTION AND PERFORMANCE
Standard dimensions: ISO 15552, ISO 21287, ISO 6432
Barrel diameter (bore) (mm)
Rod diameter (mm)
Stroke (mm)
SPECIAL CYLINDERS
Anti-rotation cylinders
Rod-less cylinders
Telescopic cylinders
Cylinders with brake
Compact cylinders
Cylinders with diaphragm (plane, rolling, ...)
Cylinders with flexible elements (bellows, with lobes, pneumatic
muscles, ...)
Multiposition cylinders
Rotary cylinders
SPECIAL CYLINDERS
Cylinders with antirotation device
These cylinders were developed together with pneumatic
manipulator and meet the requirement of keeping the same
orientation of the clamping device and workpiece.
Different solutions are available: non circular rod, non circular
barrel, twin rod, cylinders pair, external guides.
SPECIAL CYLINDERS
Non circular rod (or barrel): different shapes for rod (or barrel) are possible (hexagonal,
square, … for the rod, elliptical, rectangular, …for the barrel). Both seals and sliding
bearings must be shaped at the same way. Rounded edges are more advisable in order to
avoid damages to the seal.
Elliptical barrel
This solution is able to withstand to high torques

and enables to save space in comparison with
circular cylinders.
Hexagonal rod Batch mounting
(array) of
rectungular
cylinders.
SPECIAL CYLINDERS
Twin rods: the rods are connected together by means of a plate; the rods combine both the
thrust and guide action.
Twin rods Cylinder with external guide: this solution
provides a sliding unit
Twin pistons: this solution provides a

sliding unit; these units can be
combined in a modular way.
Cylinder Guiding element

SPECIAL CYLINDERS
Rod-less cylinders
Rodless cylinders are specialized pneumatic components capable of
moving slides through strokes that may be as much as several meters
long, but feature a more compact design than conventional cylinders.
Rodless cylinders are of double acting type and are ideal for
compact installations or applications where space is limited.
Different solutions are possible: sealing band cylinders with slotted
barrel, cable cylinders, magnetically coupled cylinders.
SPECIAL CYLINDERS
Rod-less cylinders: longitudinal slot and sealing band
The barrel consists of aluminum profiles closed by means of two
end caps whereby the actuator is secured and the chambers can be
supplied. As shown in the figure, the slide runs lengthwise along
the top of the barrel to move the external load. The external slide is
connected to the piston inside the barrel by means of a longitudinal
slot in the barrel's aluminum body.
SLIDE
BARREL
SPECIAL CYLINDERS
Cross sections through the cylinder: one can see the lengthwise slot (1) whereby the piston
(2) can be connected to the external slide (3) to which the load will be secured. Sealing is
accomplished by means of an internal metal band (4) which closes off the slot in the area
which is not engaged by the piston; the band then enters the piston, passing internally. The
piston is provided with two lip seals (5) which isolate the two actuator chambers. These
seals also contact the inner surface of the band. As the cylinder moves, the flexible band
adapts to the changing positions of the piston and slide. A second, outer band (6) covers the
slot to prevent the ingress of impurities and foreign bodies.
SPECIAL CYLINDERS
Advantages:
Example of applications
Reduced overall dimensions when long strokes are
required (ideal for compact installations or applications
where space is limited).
Optimal system performance by combining multi-axis
cylinder combinations.
Drawbacks:
Rather complex and costly.
Machining involves a high degree of precision for a
number of components:
- guide bearings for the piston-slide system (motion
with little machining gap and withstanding bending and
torsional moments);
- members that seal and limit leakage from the cylinder
(sealing mechanism provided by the band-slot and
piston-seal system – the band precision machining is
particularly important).
SPECIAL CYLINDERS
Rod-less cylinders: cable cylinder, band cylinder
The piston (P) of double acting cylinder
is connectected to two cables (1) and (2)
by means of two pulleys (3) and (4).
The cables are engaged with a
guiding/sealing element (S).
The regulation element (5) allows the
cables blockage and to adjuste the
tension.
(5) external slide
While the piston (P) performs the stroke the
element (5) slides transmitting the motion to BAND
the operated device.
Drawbacks:
Limit due to the fatigue resistance of
the cable and the band.
SPECIAL CYLINDERS
Rod-less cylinders: magnetically coupled
The magnetic slide rod-less cylinder
Magnetic slide
operates pneumatically and is equipped
with a piston and a slide with magnets.
The piston is inside the cylinder barrel.
The slide runs along the cylinder barrel
following the piston movement thanks
to the magnetic coupling force. If an
Cylinder barrel axial force exeeding the magnetic
coupling is applied to the slide this
disengages.
The cylinder can be secured at the end by means of nuts, flanges or brackets.
The length can be of several meters so that these actuators provide actual linear
trasportation systems.
SPECIAL CYLINDERS
Rod-less cylinders: magnetically coupled
T: cylindrical tube (stainless steel);
P: piston sliding inside the tube;
MP: permanent magnets embedded into
the piston;
MS: permanent magnets embedded into
the slide;
S: slide;
H: cylinder head;
Advantages: B: sliding bearing.
Compact installations.
Optimal system performance by combining multi-axis
cylinder combinations.
Drawbacks:
Limit due to the max. magnetic coupling Curved tube
force.
Weight of the magnets.
SPECIAL CYLINDERS
Telescoping cylinders Symbol
Telescoping cylinders provide a relatively long stroke

combined with mechanical strength. They are made of
a series of extension barrels, with progressively
2° stage reduced diameter bore, and nested one inside each
Retracted other.
They are available as single or double acting cylinders
1° stage and can consist of up to 5 telescoping sleeves.
They work in optimal conditions when the load is
axial.
Extended
Drawbacks:
Relatively expensive compared to standard
cylinders.
SPECIAL CYLINDERS
Telescoping cylinders
Comparion of overall dimensions
2 stages telescopic cylinder
3 stages telescopic cylinder
Advantages:
Very long stroke from a very compact retracted length.
SPECIAL CYLINDERS
Cylinders with brake
The brake avoids non –controlled movement of the cylinder for safety.
Usually the brake is an additional device applied to a standard pneumatic cylinder
(mainly at the front head).
Cylinder with shoe brake

It consists of a ring (1) which press the
clamp (2) against the piston-rod (R) of
the cylinder. The movement is
performed by the rocking-levers (3)
actuated by the piston (4) through the
tapered surface and the rollers.
The brake operates as a safety systems
(without air) thanks to the spring (5).
Supply pressure through the inlet (6)
enable to release the brake. Pressure
in the inlet (7) increases the action of
spring (5).
Pivot point of the lever
SPECIAL CYLINDERS
Cylinders with compact overall dimensions
This type of cylinder is used in modern devices and equipments where the need of
reduced dimensions is an important requirements. Typical applications are equipments
for the clamping of working pieces (vise cylinders).
The scheme on the left shows a compact cylinder in

which both heads (front and rear one) are manufactured
inside the overall axial dimension of the cylinder.
The scheme on the right shows a solution where one of

the two heads (the rear one) is machined in the body of
the cylinder barrel.
SPECIAL CYLINDERS
Cylinders with compact overall dimensions
Both double acting and single acting compact cylinders are available.
Here is shown a scheme of single acting cylinder and a
picture in order to have an idea of overall dimensions.
These types of cylinders
are not provided of
adjustable end stroke
cushions.
Cylinder bore below 20

mm are available (∅8, 12
mm).
Comparison of overall dimensions of a

pneumatic vice with traditional cylinders
(ISO 15552) and compact cylinders (ISO
21287).
SPECIAL CYLINDERS
Mini and micro cylinders
These types of cylinders are of late development and particularly for textile and mini-
handling applications. Both double acting and single acting compact cylinders are
available.
These types of cylinders are not provided of

adjustable end stroke cushions.
Cylinder bore below 20 mm are available (∅8, 12

mm). Dimensions are referred according to standard
ISO 6432.
On the left are shown two typical examples based on

a “cartridge” solution. These cylinders are defined to
be tightened directly on the supply hole (circle in
blue) and on the panel board of an automatic
machine.
Panel board of an automatic machine

SPECIAL CYLINDERS
Cylinders with diaphragm
They are of single-acting types and are available according to two main design:
Diaphragm cylinders;
Rolling diaphragm cylinders.
A built-in diaphragm made of rubber, plastic or metal performs the task of the piston.
The piston rod is mounted centrally on the diaphragm. There are no sliding seals, but
merely friction as a result of the tensile stress of the diaphragm.
They are used in short stroke applications, for clamping and lifting operations (robot
handling, pneumatic vices, grippers).
Diaphragm cylinders
SPECIAL CYLINDERS
Cylinders with diaphragm
Below a solution for a single effect cylinder with a plain diaphragm. The diaphragm is
secured around its perimeter to the cylinder barrel and around its middle to the piston;
this prevents any leakage of air between the two chambers.
This cylinder is suitable to work with short stroke
and is mainly employed for generating the braking
force in wheel brakes for lorries and busses.
These cylinders are also applied in food industries
because they do not require lubrication and therefore
do not exhaust oil mist.
Force (daN)
Diaphragm cylinders
Stroke (mm)
SPECIAL CYLINDERS
Rolling-diaphragm cylinders
The rolling diaphragm is a sleeve which rolls from the cylinder barrel to the piston as this
latter moves forward and backward. The rolling diaphragm performs larger strokes than
those of the diaphragm cylinder (max. of about 150 mm).
The rolling action makes the cylinder almost free of break-

away and dynamic friction. Suitable for applications where a
position or force control is needed.
The diaphragm can be made from a

wide variety of elastomers (fabric
reinforced) also suitable for almost
any aggressive chemical condition.
Rolling-diaphragm cylinder
Applications: wheel brakes,
perfect sealing systems, food and
drug industries, chemical
processes.
SPECIAL CYLINDERS
Bellows
Bellows actuators are of a rubber made structure which extends under the supply pressure
action. Usually they are made of rubber (elastomer) reinforced with fabric. Since they do
not have mechanical moving elements friction force does not exist.
Bellows are very robust actuator and can work under severe conditions: underwater
installations, dirty or dusty environment. end cap
single convolution
double convolution
Bellow types actuators
The permissible tilt angle between the two end
caps is much higher than those of standard
cylinders. Do to their compliance they can
accommodate loads varying in angle up to
30°.
SPECIAL CYLINDERS
Bellows
They require external restraints to limit the maximum extension and compression.
The load must be supported by external stops when the bellows are exhausted.
Due to the compliance during pressurization, an extension of the elastic elements is
obtained with a reduction of the active area (the effective diameter changes when it
extends). This entails a decreasing force with increasing stroke.
Range of strokes: 70 – 550 mm.

Pressure range: 6-10 bar.
Applications:
• mechanical actuators
• vehicular suspensions
• vibration isolation systems
SPECIAL CYLINDERS
Pneumatic muscle
The first pneumatic muscle was developed by McKibben: it consists of a bladder
surrounded by a braided mesh shell, with flexible but not-extensible fibers, that is attached
at either ends.
F
x When the actuator is pressurised, due to the non-extensibility of
the fibers (threads) in the braided mesh, the actuator shorten and
produces an external tension load. The tensile force depends
heavily on the contraction.
A slightly stretched muscle give the maximum force, the
completely contracted muscle generate no force.
F
Pneumatic muscle develops rather high forces with a good

weight/power ratio.
Applications:
• unconventional robotics
(walking robots)
SPECIAL CYLINDERS
Pneumatic muscle
pressurised
unpressurised
SPECIAL CYLINDERS
Flexible actuators
Below the scheme of an actuator used as a mechanical finger grip.
The structure, made of elastomer, is not axisimmetric and

made of a smooth part and a corrugated one.
When the actuator is pressurized the chamber expands,
the smooth part do not change its length and the
corrugated part lengthen. This behavior results in a bend
of the actuator making it suitable for gripping of soft
workpieces and with irregular shape.
SPECIAL CYLINDERS
Multi-position cylinders
Multi-position cylinders are usually obtained connecting together two double acting
cylinders with the piston-rods on opposite sides. In the example two standard cylinders,
double acting, are mounted back to back. The left rod end is fixed; 4 fixed positions are
available, at the right rod end, by fully instroke or outstroke the cylinders in all possible
combinations.
Drawbacks:
Cylinder barrels are not fixed but moving;
This increases the load mass and requires a solid
mechanical design.
Multi-position cylinder by interconnecting

standard cylinders
SPECIAL CYLINDERS
Multi-position cylinders
Multi-position cylinders are obtained interconnecting together two or more double
acting cylinders. A number of fixed positions are available by fully instroke or
outstroke the cylinders in all possible combinations. In the example a custom built
cylinder is shown.
X X X Figure shows a scheme of a multi-position cylinder
with 3 positions. The cylinder on the left is a
stroke-limiter for the cylinder on the right (main
cylinder). The limiter cylinder inserts its rod into
the main cylinder; only the rear chamber of the
P1 P2 P3 limiter can be pressurized.
2 3
1 Combinations of pressure signals:
X1: P1=0, P2=0, P3=1
X2: P1=1, P2=0, P3=1
X3: P1=0, P2=1, P3=0
Custom built multi-position cylinder

SPECIAL CYLINDERS
Tandem cylinders
Two pistons are mounted on one common piston rod to almost double the rod force.
Conversely to a multi-position cylinder only two ports are necessary.
Tandem cylinders enable to obtain the required force with reduced overall dimension of
the component.
Advantages: applications where the radial overall
dimensions do not allow the use of big cylinder bore
diameter.
SPECIAL CYLINDERS
Semi-Rotary cylinders
A rotary actuator is a compact device for producing torque from pneumatic pressure. It
is usually limited to one revolution or less and can provide oscillating motion as well as
high and constant torque. The two most commonly used in industrial applications are:
rack and pinion and vane.
Rack and pinion: are based on a pneumatic cylinder that uses a rack and a pinion to
convert linear motion to rotation. This type of actuators are often used in the process
industry to operate valves.
The advantage of this design is a
uniform torque for a constant
pressure. For high request of
torque a twin cylinder can be
used.
Semi-rotary cylinder
SPECIAL CYLINDERS
Semi-Rotary cylinders
Vane type cylinders: are compact drive consisting of a vane attached to a shaft (the rotor)
which is assembled into a body (the barrel) and then held in place by two heads. If air
enters through the port 1, it pushes the vane and generates a torque on the shaft. The air in
the opposite chamber is discharged through the port 2 until the vane stops. The opposite
rotation is obtained when supplying port 2.
The possible angular rotation for a single vane is about 270°.
Torque range: 10-3000 Nm (pressure 7 bar).
Two vanes design is also available with
∼ twice the torque of the single vane;
the angle of rotation is limited to ∼ 90°.
Vane cylinder

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Mechatronic Engineering: Fluid Automation

Unit 3 – Pneumatic actuators

Classification: Use the energy in compressed

• Pneumatic motors. Capable of performing continuous

Push cylinder Pull cylinder

Graphic symbols of pneumatic components

Single acting cylinder

Double acting cylinder

Double acting cylinder

Double acting cylinder

PNEUMATIC SYSTEMS: PNEUMATIC CIRCUIT COMPONENTS

INLET FLOW OULET FLOW

PNEUMATIC SYSTEMS: PNEUMATIC CIRCUIT COMPONENTS

END STROKE CUSHIONING

Adjustable screw Shaped sleeves

Cushion seals Main flow passage (closed)

Dynamic: between piston and

Chamber 2 Chamber 1 P1>P2

The sealing force is radial, and is augmented by the pressure in the

Cylinder mounting arrangements.

Barrel diameter (bore) (mm)

Rod diameter (mm)

This solution is able to withstand to high torques

Twin pistons: this solution provides a

Cylinder Guiding element

Telescoping cylinders provide a relatively long stroke

2 stages telescopic cylinder

3 stages telescopic cylinder

Cylinder with shoe brake

The scheme on the left shows a compact cylinder in

The scheme on the right shows a solution where one of

Cylinder bore below 20

Comparison of overall dimensions of a

These types of cylinders are not provided of

Cylinder bore below 20 mm are available (∅8, 12

On the left are shown two typical examples based on

Panel board of an automatic machine

The rolling action makes the cylinder almost free of break-

The diaphragm can be made from a

Range of strokes: 70 – 550 mm.

Pneumatic muscle develops rather high forces with a good

The structure, made of elastomer, is not axisimmetric and

Multi-position cylinder by interconnecting

Custom built multi-position cylinder

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