Pneumatic Components - Handouts

Pneumatic Components Air is used as medium, Why?
 Abundant
 Safe
 Cheap
 Easy to Maintain
 Exhausted to atmosphere
Dr. M. Puviyarasan
Associate Professor in Mechanical Engineering,
With Significant Contributions from
Panimalar Engineering College, Chennai-600 123. M r. S . Um a sh a n k a r
Graduate Student, Class of 2019
22 April 2021 Slide 3
Dr. M. Puviyarasan, Associate Professor, Panimalar Engineering College, Chennai.
About pneumatic Advantages of Pneumatic System

 Pneuma → air, wind, breath  Inertia effect of pneumatic components are less.(Density)
 Branch of study which deals with the behaviour and application of  Lesser frictional pressure and power loss. (Viscosity)
compressed air.  Can be exhausted to atmosphere after completing its assigned task.
 System uses pressurized gas to transmit and control power  Special reservoirs and No-leak system designs are not needed.
 Lesser in weight of equipment.
Limitations
 Precise actuator control and precise positioning control is not possible
(Because of high compressibility).
 Can be only applied for low pressure applications.
22 April 2021 Slide 2 22 April 2021 Slide 4

Dr. M. Puviyarasan, Associate Professor, Panimalar Engineering College, Chennai. Dr. M. Puviyarasan, Associate Professor, Panimalar Engineering College, Chennai.
Applications Basic Laws
 Stamping  Boyle's law
 Punching a law stating that the pressure of a given mass of an ideal gas is inversely
proportional to its volume at a constant temperature.
 Riveting
 Charle’s law
 Hammering
a law stating that the volume of an ideal gas at constant pressure is directly
 Drilling proportional to the absolute temperature.
 Assembling
 Gay Lussac’s law
 Material Handling when volume is held constant, the pressure of an ideal gas is directly
 Hoisting proportional to its temperature.
 Clamping
In General PV/T = Constant
 Logical Controlling

Selection Boyle's law
Speed Pressure Feed/Positioning System
-- Very High Extremely Accurate Oil Hydraulics
High Medium Fairly Accurate Air Pneumatics
Combination of Air and

-- Medium Greater Accuracy
Hydraulic System

Charle’s law Basic Laws
 Boyle's law
a law stating that the pressure of a given mass of an ideal gas is inversely
proportional to its volume at a constant temperature. P1V1=P2V2
 Charle’s law
a law stating that the volume of an ideal gas at constant pressure is directly
proportional to the absolute temperature. V1T2=V2T1
 Gay Lussac’s law
when volume is held constant, the pressure of an ideal gas is directly
proportional to its temperature. P1T2=P2T1
In General PV/T = Constant

Gay Lussac’s law COMPONENTS OF PNEUMATIC SYSTEM

Typical Pneumatic Device System AIR COMPRESSORS

AIR COMPRESSORS PISTON TYPE RECIPROCATING COMPRESSOR
Single stage compressor

PISTON TYPE RECIPROCATING COMPRESSOR Labyrinth
 Labyrinth Piston is an assemblage type piston.
 In the periphery many Labyrinths are treated,
and keeps airtight condition by Labyrinth
Effect.
 The piston is designed in the most suited
Labyrinth shape and reciprocates keeping the
minimum gas between cylinder and piston.
Multi stage  Labyrinth Piston Type Compressor is

compressor designed to be airtight construction with
Labyrinth effect and the gas with normal
•Wide Range of Capacity and Pressure •Single cylinder compressor – up to 10 bars specifications can be procured at completely
•Overall efficiency is high •Multi cylinder compressor – up to 16 bars dried condition.
•High Pressure, High Volume using Multi-stage •1250 m3/hr.
•Mechanical Balancing – Multi Cylinder
Parts of reciprocating air compressor

Rotary vane compressor Screw Compressor

Rotary vane compressor Screw Compressor
• Pulsation free
• Smaller Size
• Light Weight
• High Speed
• 3 to 10 bars
• Low Pressure
• 3000 m3/hr
• Large Quantity • Steady delivery without pressure pulses • No need of receiver
• Up to 8 bars • 2500 m3/hr
Symbol for compressor Fluid Conditioners
 Air filter, pressure regulator and lubricator are now built as
packaged combination known as service units.
 Other than the impurities that might be entrained with the intake air
and delivered by the compressor air might pick up contaminants
such as dust, scale or rust particles in the distribution main leading to
the take-off point.
 Provided that air main has been properly installed, the major part of
these impurities will collect in the condensate drain tanks.

Comparison of different compressors Fluid Conditioners

 Minute particles remain suspended in the air stream however and
would damage the working parts of pneumatic components by their
abrasive action were they are removed beforehand.
 Furthermore the air flow in the main pulsated, due, for one thing, to
the compressor running intermittently as controlled by pressure in
air receiver. The consumer, on the other hand, need to work with a
uniform air pressure.
 Finally, lubrication is required for the moving parts of the pneumatic
equipment.

Fluid conditioners Source of contamination
 The purpose of the fluid conditioners is to make the compressed air  The quality of air being drawn into the compressor
more acceptable and suitable fluid medium for the pneumatic system  The type and operation of the air compressor
as well as the operating personal.  Compressed air storage devices and distribution systems
 Types of contamination in a compressed air system
Elements of fluid conditioner
 Atmospheric dirt
 Filters  Water vapour, condensed water and water aerosols
 Regulator  Rust and pipe scale
 Lubricator  Micro-organisms
 Liquid oil and oil aerosols
 Muffler
 Oil vapour
 Air dryers

Air Filter Factors affecting selection of filters

 The purpose of the air filter is to clean the compressed air of all  Size of particles to be filtered from the system
impurities and any condensate it contains.  Capacity of the filter
 Function of air filters  Accessibility and maintainability
 Life of the filter
 To remove all foreign matter and allow dry and clean air flow without
restriction to regulator and then to the lubricator  Ability to drain the condensate
 To condensate and remove water from the air
 To arrest fine particles and all solid contaminants from air
 Usually in line filter elements can remove contaminants in the 5-50
micron range.

Air filter - Construction Definition and typical applications of the seven qualities of air
angled louvers

Air Filter
• Air enters the inlet port of the air filter through angled louvers
• air to spin
• centrifugal action
• baffle prevents turbulent air from splashing water
• 5-50 microns
• The pressure difference between inlet and outlet will indicate the degree
to which the filter element is clogged.
• Commercially available filters have many additional features like
automatic drain facility, coalescing type filter element, service life
indicator etc.

Air pressure regulator Air pressure regulator
Function: To maintain working pressure virtually constant regardless
of fluctuations of the line pressure and air consumption.
 When the pressure is too low, it results in poor efficiencies.
 when the pressure is too high, energy is wasted and equipment’s
performance decay faster.
 In pneumatic system, pressure fluctuations occur due to variation in
supply pressure or load pressure.
 It is therefore essential to regulate the pressure to match the requirement
of load regardless of variation in supply pressure or load pressure.

Where to regulate Classification

Pressure is regulated in pneumatic system at two places.  Two types of Pressure regulators
 At the receiver tank i) Diaphragm type regulator
 In the load circuits ii) Piston type regulator
 Diaphragm type regulator is commonly used in Industrial
 Pressure regulation at the receiver tank is required as a safety
pneumatic system.
measure for the system.
 There are two types of diaphragm type regulator
 In the load circuits, pressure regulator is used to regulate the
i) Non- reliving or non-venting type.
pressure for downstream components such as valves and actuators. ii) Relieving or venting type

Air pressure regulator diaphragm type Air pressure regulator piston type
Non-venting type pressure regulators
Venting type pressure regulators

Air pressure regulator Air lubricator

Function of Air Lubricator Air lubricator
 Due to this pressure difference between the upper
Function: To add a controlled amount of oil with air to ensure proper chamber and lower chamber, oil will be drawn up
lubrication of internal moving parts of pneumatic components. in a riser tube.
 Oil droplets mix with the incoming air and form a
 Lubricants are used to fine mist.
 To reduce the wear of the moving parts  The needle valve is used adjust the pressure
differential between across the oil jet and hence
 Reduce the frictional losses the oil flow rate.
 Protect the equipment form corrosion  The air – oil mixture is forced to swirl as it leaves
the central cylinder so that large particles of oil is
 The lubricator adds the lubricating oil in the form of fine mist to goes back to bowl and only the mist goes to outlet.
reduce the friction and wear of moving parts of pneumatic  The lubricator starts to operate only when there is
sufficient flow of air.
components such as valves, packing used in air actuators.  Only thin mineral oil may be used in pneumatic
system lubricator. Viscosity ratings are normally
10-50 Centistokes or SAE 10 .
Excessive lubrication is undesirable FRL unit

Excessive lubrication may results in
 malfunctioning of components,
 seizing and sticking of components after prolonged downtime
 environmental pollution

FRL unit Air Distribution
The air distribution should take into account the following parameters
1. Choice of fluid conductor
2. Flow resistance
3. Correct sizing of pipes
4. Correct sizing of fittings.
5. Pipe layout

Typical Air distribution system Mufflers

Mufflers Mufflers
 Factors affecting
 intermittent or continuous use
 the cleanliness of supplied air
 amount of oil or dirt in the environment.
 Malfunction of pneumatic equipment can all affect the insert's service
life.
 At the end of its service life, the insert need only be replaced — not
the entire muffler.

Mufflers Reason for cooling the compressed air

 Cools the air discharged from air
compressors via the heat exchanger
 Reduce risk of fire (Hot compressed
air pipes can be a source of ignition)
 Reduce compressed air moisture level
 Increase system capacity
 Pneumatic muffler minimizes exhaust air noise  Protect downstream equipment from
 Comprised of a rugged polymer housing with a replaceable acoustic composite excessive heat
insert, designed to effectively quiet the exhaust on air-operated equipment.
 It is porous to air and fluids, helping to minimize back pressure.

Moisture Separator and in-built coolers Air dryer
 A moisture separator installed at the discharge of the after cooler removes most
of the liquid moisture and solids from the compressed air.
 Utilizing centrifugal force, moisture and solids collect at the bottom of the
moisture separator. An automatic drain should be used to remove the moisture
and solids.
 Compressor manufacturers may include after coolers within the compressor
package. Absorption Dryer Deliquescent Dryer
 In general these compressors are referred to as integral after coolers.
 A stand-alone or freestanding after cooler is a separate unit installed
downstream of the compressor.
 Air - Cooled
 Water - Cooled
Refrigerated Dryer

Dryers : Function Absorption Dryer

 To lower the dew point of the compressed air by removing the  Absorption drying is a purely chemical
process.
moisture from it.
 The moisture in the compressed air forms a
 For simple applications, to remove excess humidity, we need compound with drying agent like
phosphoric pentaoxide in the tank.
simple after cooler, an air receiver, and a filter with condensate
 This causes the drying agent to break down.
traps.  It is then discharged in the form of a fluid at
 However, to get high quality compressed air additional means of the base of the tank.
 Oil vapour and oil particles are also
dehydration must be provided using dryer. separated in the absorption dryer.
 Large quantities of oil have an effect on the
Dew Point : The atmospheric temperature (varying according to pressure and humidity) efficiency of the dryer.
below which water droplets begin to condense and dew can form.  Therefore it is advisable to include a fine
filter in front of the dryer.
Absorption Dryer Adsorption type dryer (+)
 Pellets made of dehydrated chalk/calcium chloride
Advantages of Absorption dryer
1. Simple to install
2. Low mechanical wear because there is no moving parts
3. No external energy requirement
Disadvantages of Absorption dryer

1. Maintenance cost / Consumable cost is high
2. Low efficiency

Adsorption type dryer Adsorption type dryer

 Adsorption is a physical process of moisture removal on the porous
surface of certain granular materials.
 Gaseous molecules are attracted to certain solid surfaces by van der walls
forces and this causes the adsorption.
 The degree of attraction or adsorption depends on properties of gaseous
molecules and desiccant.
 Desicant – Chemical with affinity to water
 Most commonly used desiccants are activated alumina, molecular sieves
and silica gel.
(Activated alumina is an aluminum hydroxide, which is highly porous and
exhibits tremendous surface area. This desiccant is resistant to thermal shock and
abrasion and will not shrink, swell, soften when immersed in water.)

Adsorption type dryer Refrigerated Dryer
 Wet incoming compressed air after passing through a pre-filter is  It is composed of a heat exchanger (stage1) and a refrigerating unit
directed to the adsorption chamber containing the desiccant. (Stage 2) to reduce the temperature of the compressed air.
 Water vapour in the compressed air is absorbed by the desiccant.  The incoming warm and humid air is first passed through the air–to-
 Thereafter dry air is allowed to pass to the application through air heat exchanger, and then through the refrigerating unit to reduce
the after filter. the temperature of the compressed to as low as +2C.
 Adsorption dryers usually have two desiccant filled chambers with  This drying method is based on the principle that if the compressed
interconnecting piping and switching valves. air is cooled to a temperature below the dew point, condensation
takes place and water is precipitated.

Adsorption type dryer (+) Refrigerated Dryer

 The valves permit removal of the collected moisture from one chamber
while the other chamber is used to purify the compressed air.
 The twin tower design facilitates simultaneous compressed air drying and
saturated desiccant regeneration for non-stop production.
 A contaminated desiccant bed can be regenerated by either elevating its
temperature or by decreasing its pressure and purging.
 The capacity of the desiccant bed is limited owing to abrasion and
contamination of the adsorption medium by oil and other substances.
 Under normal conditions, it is required to replace the drying agent once in
2 to 3 years.

Refrigerated Dryer Membrane dryer
 Almost all the water and oil particles get condensed, and collected in  In this of dryer, pre-cleaned compressed air is passed through a bundle of
the water traps provided at appropriate points. hollow fibres in the membrane module.
 The cooled compressed air is then filtered to remove from it the  The hollow fibres constitute a membrane layer specially designed to
attract the water vapour inside.
suspended solid particles and most of the oil mist.
 This water vapour diffuses through the very thin selective layer until it
 The pressure dew point of 2 C is possible with this type, which is reaches the outside of the membrane due to partial pressure difference
sufficient enough for the smooth operation of the most of the industrial between inside and outside of the membrane.
and process applications.  The permeated water vapour is then swept away by a small amount of dry
air fed back along the length of the membrane fibre through a purging
valve.

Membrane dryer Advantages of Membrane dryer

 Stage 1: Contains a filter which removes the water and contaminants down to 1.Membrane dryers typically maintain a pressure dew point of 0C.
5 micron.
2. Membrane dryers are simple and compact
 Stage 2: High efficiency coalescing filter removes oil and sub micron particles
down to 0.01 micron. 3. Dryers run almost noiseless
 Stage 3: membrane module removes the remaining moisture in the vapour 4.There is no need for regeneration because membranes never gets
form. saturated
5. They do not require electric supply
6. Low operating cost

Symbols CHECK VALVE

Air Control Valves ::Functions CHECK VALVE

 To start and stop pneumatic energy
 To control the directional flow of compressed air.
 To control the flow rate of the compressed air
 To control the pressure rating of the compressed air.
TYPES OF AIR CONTROL VALVE

BASED ON FUNCTION  PRESSURE CONTROL VALVE
 DIRECTIONAL CONTROL VALVE  FLOW CONTROL VALVE
1. CHECK VALVE BASED ON CONSTRUCTION
2. SHUTTLE VALVE  POPPET TYPE VALVE
3. TWO WAY D.C VALVES  SLIDING SPOOL TYPE VALVE
4. THREE WAY D.C VALVES
 ROTARY SPOOL VALVE
5. FOUR WAY D.C VALVES

TWO WAY DC VALVE THREE WAY DC VALVE

FOUR WAY DC VALVE

SHUTTLE VALVE (Spool Valve/Dynamic Seals)

Quick exhaust valves

 It may be possible to induce higher speed in a cylinder by avoiding
the exhaust air to pass through the direction control valve from the
cylinder so that the air energy can act quickly.
 When the air is fed to the piston side of the cylinder, the air in the
rod-end side of the cylinder can be exhausted to the atmosphere
quickly by using a special valve. This valve is called a quick-exhaust
valve.

Quick exhaust valves Quick exhaust valves

Quick exhaust valves PRESSURE REGULATING VALVE

FLOW CONTROL VALVE Pneumatic actuator
 Types are
 Linear actuator
 Rotary actuator

Symbols Linear actuators

Guess !! Pneumatic rotary actuators

Types :--
 Continuous rotary air motors
 Gear motors
 Vane motors
 Piston motors
 Limited rotation air motors
 Vane type
 Piston type

Specify?? Time delay valve

Vane Type Limited Rotation Motors Rodless cylinder

Rodless cylinder Filter symbol and possible location

Vacuum suction cup

Seals Seals

The dream begins, most of the time, with a teacher who believes in
you, who tugs and pushes and leads you on to the next plateau,
sometimes poking you with a sharp stick called truth.
- Dan Rather
THANK YOU !
muthupuvi@gmail.com
22 April 2021 Slide 106

Dr. M. Puviyarasan, Associate Professor, Panimalar Engineering College, Chennai.

Pneumatic Components - Handouts

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Pneumatic Components Air is used as medium, Why?

About pneumatic Advantages of Pneumatic System

22 April 2021 Slide 2 22 April 2021 Slide 4

22 April 2021 Slide 5 22 April 2021 Slide 7

Selection Boyle's law

Speed Pressure Feed/Positioning System

-- Very High Extremely Accurate Oil Hydraulics

High Medium Fairly Accurate Air Pneumatics

Combination of Air and

22 April 2021 Slide 6 22 April 2021 Slide 8

In General PV/T = Constant

22 April 2021 Slide 9 22 April 2021 Slide 11

Gay Lussac’s law COMPONENTS OF PNEUMATIC SYSTEM

22 April 2021 Slide 10 22 April 2021 Slide 12

22 April 2021 Slide 13 22 April 2021 Slide 15

AIR COMPRESSORS PISTON TYPE RECIPROCATING COMPRESSOR

Single stage compressor

Multi stage  Labyrinth Piston Type Compressor is

Parts of reciprocating air compressor

22 April 2021 Slide 18 22 April 2021 Slide 20

22 April 2021 Slide 21 22 April 2021 Slide 23

Rotary vane compressor Screw Compressor

22 April 2021 Slide 25 22 April 2021 Slide 27

Comparison of different compressors Fluid Conditioners

22 April 2021 Slide 26 22 April 2021 Slide 28

22 April 2021 Slide 29 22 April 2021 Slide 31

Air Filter Factors affecting selection of filters

22 April 2021 Slide 30 22 April 2021 Slide 32

22 April 2021 Slide 33 22 April 2021 Slide 35

22 April 2021 Slide 34 22 April 2021 Slide 36

22 April 2021 Slide 37 22 April 2021 Slide 39

Where to regulate Classification

22 April 2021 Slide 38 22 April 2021 Slide 40

Non-venting type pressure regulators

Venting type pressure regulators

Air pressure regulator Air lubricator

22 April 2021 Slide 42 22 April 2021 Slide 44

Excessive lubrication is undesirable FRL unit

22 April 2021 Slide 46 22 April 2021 Slide 48

22 April 2021 Slide 49 22 April 2021 Slide 51

Typical Air distribution system Mufflers

22 April 2021 Slide 50 22 April 2021 Slide 52

22 April 2021 Slide 53 22 April 2021 Slide 55

Mufflers Reason for cooling the compressed air

22 April 2021 Slide 54 22 April 2021 Slide 56

22 April 2021 Slide 57 22 April 2021 Slide 59

Dryers : Function Absorption Dryer

Disadvantages of Absorption dryer

22 April 2021 Slide 61 22 April 2021 Slide 63

Adsorption type dryer Adsorption type dryer

22 April 2021 Slide 62 22 April 2021 Slide 64

22 April 2021 Slide 65 22 April 2021 Slide 67

Adsorption type dryer (+) Refrigerated Dryer

22 April 2021 Slide 66 22 April 2021 Slide 68

22 April 2021 Slide 69 22 April 2021 Slide 71

Membrane dryer Advantages of Membrane dryer

22 April 2021 Slide 70 22 April 2021 Slide 72

22 April 2021 Slide 73 22 April 2021 Slide 75

Air Control Valves ::Functions CHECK VALVE

TYPES OF AIR CONTROL VALVE

22 April 2021 Slide 74 22 April 2021 Slide 76

22 April 2021 Slide 77 22 April 2021 Slide 79

FOUR WAY DC VALVE