IN-HOUSE TRAINING REPORT PNEUMATIC SYSTEM ETAT-362 SUBMITTED TO SUBMITTED BY DR. VINEET KUMAR VISHAL SINGH 00320903613 MAE 6TH SEMESTERTable of Contents Acknowledgement . Introduction 1.1 Comparison of Hydraulic and Pneumatic System 1.2 Advantages & Disadvantages of Pneumatic System 1.3 Applications 1.4 Components |. Valves 2.1 Direction Control Valve 2.2 Methods of Actuation 2.3 Non-Return Valves 2.4 Flow Control Valves 2.5 Pressure Control Valves . Compressors 3.1 Piston, 32 Double Acting 3.3 Multistage 3.4 Combined Two Stage 3.5 Diaphragm 3.6 Screw 37 Rotary 38 Lobe 3.9 Dynamic 224. Actuators 28 411 Single Acting 42 Double Acting 43 Cylinder End Cushions 44 Gear Motor 45 Vane Motor 46 Limited Rotation Actuators 47 Speed Control 5. Case Study 34 References 37 Vishal Singh (00320903613) |iiAcknowledgement | take this opportunity to express our sincere gratitude to the people who have been helpful in the successful completion of our In-house training and this project. | would like to show my greatest appreciation to the highly esteemed and devoted technical staff, supervisors of our College. We are highly indebted to them for their tremendous support and help during the completion of our training and project. | am grateful to my teachers Dr. Vineet Kumar and Mr. Urfi Khan and who granted us the permission of in house training in the College. We would like to thanks to all those peoples who directly or indirectly helped and guided us to complete our training, including the instructors and technical officers of the Pneumatics Lab.Introduction Vishal Singh (00320903613) |1Pneumatics may be defined as branch of engineering science which deals with the study of the behaviour and application of compressed air to power machine or control or regulate machines. It deals with generation, transmission and control of power using pressurized air. Gas in a pneumatic system behaves like a spring since it is compressible Any gas can be used in pneumatic system but airis the most usual, for obvious reasons. Exceptions are most likely to occur on aircraft and space vehicles where an inert gas such as nitrogen is preferred or the gas is one which is generated on board. Actuation of the controls can be manual, Pneumatic or Electrical actuation. DIFFERENCES BETWEEN HYDRAULIC AND PNEUMATIC SYSTEMS One of the main differences between the two systems is that in pneumatics, air is compressible. In hydraulics, liquids are not. Other two distinct differences are given below. The pneumatic systems have two main features: © Pneumatic systems use compressed gas such as air or nitrogen to perform work processes. ‘* Pneumatic systems are open systems, exhausting the compressed air to atmosphere after use. The hydraulic systems also have two main features. © Hydraulic systems use liquids such as oil and water to perform work processes. ‘© Hydraulic systems are closed systems, recirculating the oil or water after use.HYDRAULIC SYSTEM It employs a pressurized liquid as fluid Oil hydraulics system operates at pressure upto 700 bar Generally designed for closed systems System get slowdown of leakage occurs Valve operation are difficult Heavier in weight Pumps are used to provide pressurized liquids System is unsafe to fire hazards Automatic lubrication is provided It employs a compressed gas usually air asa fluid Pneumatic systems usually operate at 5 to 10 bar Pneumatic systems are designed as open system usually Leakage does not affect the system much more Easy to operate the valves Light in weight Compressors are used to provide compressed gas System is free from fire hazards Special arrangements for lubrication needed. Table 1.1 Comparison between Hydraulic and Pneumatic Systems 320903613 13ADVANTAGES OF PNEUMATIC SYSTEM © Low inertia effect of pneumatic components due to low density of air. ‘© Pneumatic Systems are light in weight. * Operating elements are cheaper and easy to operate © Power losses are less due to low viscosity of air * High output to weight ratio © Pneumatic systems offers a safe power source in explosive environment © Leakage is less and does not influence the systems. Moreover, leakage is not harmful DISADVANTAGES OF PNEUMATIC SYSTEMS * Suitable only for low pressure and hence low force applications * Compressed air actuators are economical up to 50 KN only © Generation of the compressed air is expensive compared to electricity ‘© Exhaust air noise is unpleasant and silence has to be used Rigidity of the system is poor © Weight to pressure ratio is large * Less precise. It is not possible to achieve uniform speed due to compressibility of air * Pneumatic systems is vulnerable to dirt and contamination Vishal Singh (00320903613) [4APPLICATIONS. Pneumatic systems are used in many applications. In construction, it is indispensable source of power for such tools as air drills, hammers, wrenches, and even air cushion supported structures, not to mention the many vehicles using air suspension , braking and pneumatic tires. In manufacturing, air is used to power high speed clamping, drilling, grinding, and assembly using pneumatic wrenches and riveting machines, Plant air is also used to power hoists and cushion support to transport loads through the plant. Many recent advances in air ~ cushion support are used in the military and commercial marine transport industry. MATERIAL HANDLING MANUFACTURING OTHER APPLICATIONS Clamping Drilling | Aircraft Shifting Turning Cement Plants Positioning Milling Chemical Plants Orienting Sawing Coal Mines Feeding Finishing Cotton Mills Ejection Forming Diaries Braking Quality Control Forge Shops Bonding Stamping Machine Tools Locking Embossing Door Control Packaging Filling Turning Parts Feeding Sorting Stacking Table 1.2. Applications of Pneumatic Systems Vishal Singh (00320903613) [5COMPONENTS Pneumatic system carries power by employing compressed gas generally air as a fluid for transmitting the energy from an energy-generating source to an energy ~ se point to accomplish useful work Actuator Control valve Intake Compressor Cooler Separator filter Receiver Secondary ai treatment Prescure switch Motor control Figure 1.1 Arrangement of Pneumatic System a) Air filters These are used to filter out the contaminants from the air. b) Compressor Compressed air is generated by using air compressors. Air compressors are either diesel or electrically operated. Based on the requirement of compressed air, suitable capacity compressors may be used. Vishal Singh (00320903613) [6¢) Air cooler During compression operation, air temperature increases. Therefore coolers are used to reduce the temperature of the compressed air. d) Dryer The water vapor or moisture in the air is separated from the air by using a dryer. e) Control Valves Control valves are used to regulate, control and monitor for control of direction flow, pressure etc. f) Air Actuator Air cylinders and motors are used to obtain the required movements of mechanical elements of pneumatic system. g) Electric Motor Transforms electrical energy into mechanical energy. It is used to drive the compressor h) Receiver tank The compressed air coming from the compressor is stored in the air receiver. FUNCTIONS OF COMPONENTS * Pneumatic actuator converts the fluid power into mechanical power to do useful work, * Compressor is used to compress the fresh air drawn from the atmosphere. * Storage reservoir is used to store a given volume of compressed air. * Valves are used to control the direction, flow rate and pressure of compressed air.‘* External power supply (Motor) is used to drive the compressor. * Piping system carries the pressurized air from one location to another, Air is drawn from the atmosphere through air filter and raised to required pressure by an air compressor. As the pressure rises, the temperature also rises and hence air cooler is provided to cool the air with some preliminary treatment to remove the moisture. Then the treatment pressurized air needs to get stored to maintain the pressure. With the storage reservoir, a pressure switch is fitted to start and stop the electric motor when pressure falls and reached the required level, respectively. The cylinder movement is controlled by pneumatic valve. One side of the pneumatic valve is connected to the compressed air and silencers for the exhaust air and the other side of the valve is connected to port A and Port B of the cylinder.Valves Vishal Singh (00320903613) [9Valve are defined as devices to control or regulate the commencement, termination and direction and also the pressure or rate of flow of a fluid under pressure which is delivered by a compressor or vacuum pump or is stored in a vessel FUNCTION * They control the supply of air to power units, example cylinders «They provide signal which govern the sequence of operation * They act as interlock and safety devices Valves used in pneumatics mainly have a control function that is when they act on some process, operation or quantity to be stopped. A control function requires control energy, it being desirable to achieve the greatest possible effect with the least, effort. The form of control energy will be dictated by the valve's mode of actuation and may be manual, mechanical, electrical hydraulic or pneumatic. 1. Direction control valve 2. Non retum valves 3. Flow control valves 4. Pressure control valves Figure 2.1 Simple ValveDIRECTION CONTROL VALVES In order to control the movement of air actuators, compressed air has to be regulated, controlled and reversed with a predetermined sequence. Pressure and flow rates of the compressed air has to be controlled to obtain the desired level of force and speed of air actuators. The function of directional control valve is to control the direction of flow in the pneumatic circuit. DCVs are used to start, stop and regulate the direction of air flow and to help in the distribution of air in the required line. TYPES 1. Based on construction + Poppet or seat valves = Ball seat valve = Disc seat valve = Diaphragm Valves * Sliding spool valves = Longitudinal slide valve + Suspended spool valves = Rotary spool valves © Two way valves o Three way valves Four way valves 2. Based on methods of Actuation © Mechanical © Electrical « Pneumatic 3) 1113, Based on Size of the port Size refers to a valve's port size. The port sizes are designated as MS, G1/8, and G1/4 etc. M refer to Metric thread, G refer to British standard pipe (BSP) thread. 4, Based on mounting styles Pressure Port Working Port Working Ports Exhaust Port Exhaust Ports Pilot Ports Pilot Ports Pilot Ports Internal Pilot Ports Sub base Manifold In-line Valve island OLD (LETTER ISO (NUMBER) REMARKS SYSTEM SYSTEM P 1 Supply Port A 2 3/2 DCV AB 42 4/2 or 5/2 DCV R 3 3/2 DCV RS 53 5/2 DCV Zory 12 Pilot Line (Flow 1-2) Ez 14 Pilot Line (Flow 1-4) ZorY 10 Pilot Line (No Flow) Pz, Py 81,91 Auxiliary Pilot Line Table 2.1 Port Marking 3) [12PORT AND POSITION 2/2 directional Valve Ports Position 5 2/4) 3/2 Directional Control Valve (Normally Closed) ap) (13iR) Pal 3/2 Directional Control Valve (Normally Open ) aie) ain) say | 2) 4/2 Direction Control Valve uP}! a(R) 4A) 1218) 5/2 Direction Control Valve yn)! | | 335) a{P) sy 1208) 5/3 Direction Control Valve sini | Toys) ap} Table 2.2 Ports in different positions Vishal Singh (00320903613) |13A. Ball seat valve In a poppet valve, discs, cones or balls are used to control flow. In a simple 2/2 normally closed valve. If the push button is pressed, ball will lift off o from its seat and allows the air to flow from port P to port B. When the push button is released, spring force and air pressure keeps the ball back and closes air flow from port P to. port B. Disc seat poppet valve 2A) 1) Figure 2.2 Ball Seat Valve Ina disc type 3/2 way DCV, When push button is released, ports 1 and 3 are connected via pushbutton stem. If the push button is pressed, port 3 is first blocked by the moving valve stem and then valve disc is pushed down so as to open the valve thus connecting port 1 and 3. When the push button is released, spring and air pressure from port 1 closes the valve. hollow upp 1318) Figure 2.3 Disc Seat Poppet Valve Vishal Singh (00320903613) | 14C. Diaphragm valves The diaphragm between the actuator and valve body hermetically isolates the fluid from the actuator. Closed position: When de-energized, the valve is closed by spring action Open position: If the actuator is pressurized by the control pressure, it simultaneously lifts the control piston and the a) Unacusted ) acruated valve spindle to open the valve. Figure 2.4 Diaphragm Valve The valves are maintenance-free and extremely robust and can be retrofitted with a comprehensive range of accessories, eg, electrical position feedback, stroke limitation or manual override. Advantages of poppet valves * Response of poppet valve is very fast- short stroke to provide maximum flow opening They give larger opening (larger flow) of valves for a small stroke The valve seats are usually simple elastic seals so wear is minimum. They are insensitive to dust and dirt and they are robust, seats are self-cleaning Maintenance is easy and economical. They are inexpensive Vishal Singh (00320903613) |15‘© They give longer service life: short stroke and few wearing parts give minimum wear and maximum life capabilities Disadvantages of poppet valves © The actuating force is relatively high, as it is necessary to overcome the force of the built in reset spring and the air pressure. © They are noisy if flow fluctuation is large. SPOOL DIRECTION CONTROL VALVES A. Pneumatically actuated 3/2 DCV In normal position, the working port (2) is closed to the pressure port (1) and open to the exhaust port (3). When the compressed air is applied through the pilot port (12), the spool is moved against the spring. In the actuated position, the A) working port (2) is open to te FF the pressure port (1) and SN : closed to the exhaust port wha fA ae (3). Thus, the application of g oF the compressed air to the aT] port 12 causes the pressure | mw port (1) to be connected to | the working port (2). Figure 2.5 Pneumatically Actuated 3/2 DCV Vishal Singh (00320903613) |16B. Pneumatically actuated 4/2 DCV In a 4/2 way valve pneumatically operated DCV, Switch over is effected by direct application of pressure. If compressed air is applied to pilot spool through control port 12, it connects port 1 with 2 and 4 is exhausted through mp Dit >) Figure 2.6 Pneumatically Actuated 4/2 DCV port 3. If the pilot pressure is applied to port 14, then 1 is connected with 4 and line 2 exhausted through port 3. On disconnecting the compressed air from the control line, the pilot spool remains in its current position until spool receives a signal from the other control side. C. Suspended Disc Direction Control Valves This valve is quite similar to 4/2 way spool valve. In this design disc is used instead of a spool. This ay ps suspended disc can be moved by pilot ah tae pressure or by solenoid or by mechanical means. In this design, main disc connects port 1 to either port 4 or 2. Figure 2.7 Suspended Disc DCV ix uel Sm The secondary seat discs seal the exhaust port 3 whichever is not functional. These values are generally provided with manual override to manually move the cylinder.D. Rotary valves The rotary spool directional control valve has a round core with one or more passages or recesses in it. The core is mounted within a stationary sleeve. As the core is rotated within the stationary sleeve, the passages or recesses connect or block the ports in the sleeve. The ports in the sleeve are connected to the appropriate lines of the fluid system Figure 2.8 Rotary Valve By rotating the handle, core gets connected to different holes to give the required configuration of the valve. This type of the valve can be directly mounted on panel using bolt METHODS OF ACTUATION The methods of actuation of pneumatic directional control valves depend upon the requirements of the task. The types of actuation vary; © Manually actuated © Mechanically actuated © Pneumatically actuated Electrically actuated © Combined actuationTYPE OF ACTUATION TYPE OF CONTROL SYMBOL General Push button q_ Manual Distant lever operated bop — Foot pedal 4 — Spring return > Spring centred J Mechanical Roller Operated J Idle Roller # Direct | | Pneumatic Indirect, Pilot Operated — Single Solenoid — Electrical Double Solenoid gq iy Combined Double Solenoid with pilot operated Table 2.3 Different types of Actuation Method Vishal Singh (003205 613) |19NON RETURN VALVES Non return valves permit flow of air in one direction only, the other direction through the valve being at all times blocked to the air flow. Mostly the valves are designed so that the check is additionally loaded by the downstream air pressure, thus supporting the non-return action. Flow back prevented Inflow alowed TYPES ae — = — l “ecK\ | =. Po = (fT Figure 2.9 Non-Return Valves © Check valve . © Shuttle valve 7 |p ire © Restrictor check valve © Quick exhaust valve ul = | © Two pressure valve FLOW CONTROL VALVES A flow control valve regulates the rate of air flow. The control action is limited to the air flow passing through the valve when it is open, maintaining a set volume per unit of time. Las pst Bias Speing Variable Knife Edge ‘Compensating Ornitiee Pilot Line Figure 2.10 Flow Control Valves Vishal Singh (00320903613) [20PRESSURE CONTROL VALVE Compared with hydraulic systems, few pressure control valves are brought into use in pneumatics. Pressure control valves control the pressure of the air flowing through the valve or confined in the system controlled by the valve. Vo plight in postin by an actuate Figure 2.11 Pressure Control Valves __ Thediferentia pressure sop ‘cross the vahe = 3barg There are three types of pressure control valves 1. Pressure limiting valve 2. Pressure sequence valve 3. Pressure regulator or pressure reducing valve Vishal Singh (00320903613) [21CompressorsIt isa mechanical device which converts mechanical energy into fluid energy. The compressor increases the air pressure by reducing its volume which also increases the temperature of the compressed air. The compressor is selected based on the pressure it needs to operate and the delivery volume The compressor can be classified into two main types a. Positive displacement compressors b. Dynamic displacement compressor Positive displacement compressors include piston type, vane type, diaphragm type and screw type. Piston compressors are commonly used in pneumatic systems. It produces one pulse of air per piston stroke. As the piston moves down during the inlet stroke the inlet Ac tolet a aap Ar outlet valve opens and air is drawn into the cylinder. As the piston moves up the inlet valve closes and the exhaust valve opens which allows the | Piston air to be expelled. The valves are spring loaded. The single cylinder compressor gives an significant amount of pressure pulses at the outlet port. The pressure developed is about 3-40 bar. Figure 3.1 Piston Compressor Vishal Singh (00320903613) [23DOUBLE ACTING COMPRESSOR The pulsation of air can be reduced by using double acting compressor. It has two sets of valves and a crosshead. As the piston moves, the air is compressed on one Inlet valves Cross slide Piston inlet Outlet OutleFvalves Figure 3.2 Double Acting Compressor side whilst on the other side of the piston, the air is sucked in, Due to the reciprocating action of the piston, the air is compressed and delivered twice in one piston stroke. Pressure higher than 30bar can be produced MULTISTAGE COMPRESSOR As the pressure of the airincreases, its temperature rises. It is essential to reduce the air temperature to avoid damage of compressor and other mechanical elements. The multistage compressor with intercooler in-between. It is used to reduce the temperature of compressed air during the compression stages. The inter-cooling reduces the volume of air which used to increase due to heat. The compressed air from the first stage enters the intercooler where it is cooled. This air is given as input to the second ee B ic eae stage where it is 4 compressed again. The fis#a4e multistage compressor can develop a pressure of around 50bar. Connecting rods {Driven by same moter) Figure 3.3 Multistage Compressor Vishal Singh (00320903613) [24COMBINED TWO STAGE COMPRESSORS In this type, two-stage compression is carried out by using the same piston. Initially when the ne: piston moves down, air is sucked in through the inlet valve. During the sole amen COMPFeSSioN process, the air moves piston out of the exhaust valve into the intercooler. As the piston moves further the stepped head provided on the piston moves into the cavity thus causing the compression of air. Then, this is let out by the exhaust port. Figure 3.4 Combined Two Stage Compressor DIAPHRAGM COMPRESSOR In piston compressors the lubricating oil from the pistons walls may —e contaminate the compressed air. The contamination is jraute Nydeste undesirable in food, =“ "il oot pharmaceutical and chemical industries. For such applications diaphragm type compressor can be used. Figure 3.5 Diaphragm Compressor The piston reciprocates by a motor driven crankshaft. As the piston moves down it pulls the hydraulic fluid down causing the diaphragm to move along and the air is sucked in. When the piston moves up the fluid pushes the diaphragm up causing the ejection of air from the outlet port. Since the flexible diaphragm is placed in between the piston and the air no contamination takes place. Vishal Singh (00320903613) [25Inteemeshing screws Figure 3.6 Screw Compressor Piston compressors are used when high pressures and relatively low volume of airis needed. The system is complex as it has many moving parts. For medium flow and pressure applications, screw compressor can be used. Its simple in construction with less number of moving parts. The air delivered is steady with no pressure pulsation. It has two meshing screws. The air from the inlet is trapped between the meshing screws and is compressed. The contact between the two meshing surface is minimum, hence no cooling is required. These systems are quite in operation compared to piston type. The screws are synchronized by using external timing gears. ROTARY VANE COMPRESSORS The principle of operation of vane compressor is similar to the hydraulic vane pump. The unbalanced vane compressor consists of spring loaded vanes seating in the slots of the rotor. The pumping action occurs due to movement of the vanes along a cam ring. The rotor is eccentric to the cam ring. As the rotor rotates, the vanes follow the inner surface Rotor janes Figure 3.7 Rotary Vane Compressor of the cam ring. The space between the vanes decreases near the outlet due to the eccentricity. This causes compression of the air. These compressors are free from pulsation. If the eccentricity is zero no flow takes place. Vishal Singh (003205 613) [26LOBE COMPRESSOR The lobe compressor is used when high delivery volume but low pressure is needed. It consists of two lobes with one being driven and the other driving. It is similar to the Lobe pump used in hydraulic systems. The operating pressure is limited by leakage between rotors and housing. ‘As the wear increases during the operation, the efficiency falls rapidly. DYNAMIC COMPRESSORS When very large volume of compressed air is required in applications such as ventilators, combustion system and pneumatic powder blower conveyors, the dynamic compressor can be used, The pressure needed is very low in such applications. The impeller rotates at a high speed. Large volume of low pressure air can be provided by Inlet: Figure 3.9 Dynamic Compressor blowers. The blowers draw the air in and the impeller flings it out due to centrifugal force. Positive displacement compressors need oil to lubricate the moving parts, whereas the dynamic compressors have no such need. The efficiency of these compressors is better than that of reciprocating types. Vishal Singh (00320903613) |27Actuators 3613) 128Actuators are output devices which convert energy from pressurized hydraulic oil or compressed air into the required type of action or motion. In general, hydraulic ‘or pneumatic systems are used for gripping and/or moving operations in industry. These operations are carried out by using actuators. Actuators can be classified into three types. 1. Linear actuators: These devices convert hydraulic/pneumatic energy into linear motion. 2. Rotary actuators: These devices convert hydraulic/pneumatic energy into rotary motion. 3. Actuators to operate flow control valves: these are used to control the flow and pressure of fluids such as gases, steam or liquid. The construction of hydraulic and pneumatic linear actuators is similar. However they differ at their operating pressure ranges. Typical pressure of hydraulic cylinders is about 100 bar and of pneumatic system is around 10 bar. SINGLE ACTING CYLINDER These cylinders produce work in one direction of motion hence they are named as single acting cylinders. |The compressed air pushes the piston located in the cylindrical barrel causing the desired motion. The return stroke takes place by the action of a spring. Generally the spring is provided on the rod side of the oflinder. U-Cap Sea cyinder Body O-Ring inn Soring Figure 4.1 Single Acting Cylinder End Cover Piston RodDOUBLE ACTING CYLINDER The main parts of a hydraulic double acting cylinder are: piston, piston rod, cylinder tube, and end caps. The piston rod is connected to piston head and the other end extends out of the cylinder. The piston divides the cylinder into two chambers namely the rod end side and piston end side. The seals prevent the leakage of oil between these two chambers. The cylindrical tube is fitted with end caps. The pressurized oil, air enters the cylinder chamber through the ports provided. In the rod end cover plate, a wiper seal is provided to prevent the leakage of oil and entry of the Figure 4.2 le Acting Cylinder contaminants into the Piston sea! End seal Wiper seal gyflinder. The combination of wiper seal, bearing and sealing ring is called as cartridge assembly. The end caps may be attached to the tube by threaded connection, welded connection or tie rod connection. The piston seal prevents metal to metal contact and wear of piston head and the tube. These seals are replaceable. End cushioning is also provided to prevent the impact with end caps. CYLINDER END CUSHIONS Double acting gylinders generally contain cylinder cushions at the end of the gylinder to slow down the movement of the piston near the end of the stroke. Cushioning arrangement avoids the damage due to the impact occurred when a fast moving piston is stopped by the end caps. Deceleration of the piston starts when the tapered plunger enters the opening in the cap and closes the main fluid exit. This restricts the exhaust flow from the barrel to the port. This throttling causes the initial speed reduction. During the last portion of the stroke the oil has to exhaust through an adjustable opening since main fluid exit closes. Thus the remaining fluid exists Vishal Singh (00320903613) [30through the cushioning valve. Amount of cushioning can be adjusted by means of cushion screw. A check valve is provided to achieve fast break away from the end position during retraction motion. A bleed screw is built into the check valve to remove the air bubbles present in a hydraulic type system. Check Valve clBhion Cushioning Piston ahve Plunger Sea Figure 4.3 Cylinder End Cushions GEAR MOTOR: A ROTARY ACTUATOR It consists of two inter meshing gears inside a housing with one gear attached to the drive shaft. The air enters from the inlet, causes the rotation of the meshing gear due to difference in the pressure and produces the torque. The air exists from the exhaust port. Gear motors tend to leak at low speed, hence are generally used for medium speed Seven applications. Sete Figure 4.4 Gear Motor VANE MOTOR: A ROTARY ACTUATOR A rotary vane motor consists of a rotor with sliding vanes in the slots provided on the rotor. The rotor is placed eccentrically with the housing. Air enters from the inlet port, rotates the rotor and thus torque is produced. Air is then released from the exhaust port (outlet). Figure 4.5 Vane MotorLIMITED ROTATION ACTUATORS It consists of a single rotating vane connected to output shaft. It is used for double acting operation and has a maximum angle of rotation of about 270°. These are generally used to actuate dampers in robotics and material handling applications. Other type of limited rotation actuator is a rack and pinion type actuator. Movable vane Fixed arm Figure 4.6 Limited Rotation Actuator SPEED CONTROL For an actuator, the operational speed is determined by the fluid flow rate and the cylinder actuator area or the motor displacement. The speed can only be controlled by adjusting the fluid flow to the actuator, because the physical dimension of the actuator is fixed, Since the air is compressible, flow control is difficult as compared to the hydraulic system. There are various ways of controlling the fluid flow. a Area AOne of the method is that a pump having fixed displacement is kept along an actuator. Thus, the fluid goes either to the pump or the actuator. When the direction control valve moves fram its centre position the actuator of area ‘A’, the piston moves with a velocity. vaV/A If the pump delivery volume 'V’ can be adjusted by altering swash plate angle of a piston pump or by using a variable displacement vane pump, no further speed control will be needed. Vishal Singh (00320903613) [33Case StudyTo design a pneumatic circuit to accomplish a simple operation where a double- acting cylinder is used to transfer parts from a magazine. The cylinder is to be advanced either by operating a push button or by a foot pedal. Once the cylinder is fully advanced, it is to be retracted to its initial position. A 3/2-way roller lever valve is to be used to detect the full extension of the cylinder. Figure 5.1 Magazine Ejection Setup COMPONENTS USED The pneumatic components which can be used to implement the mentioned task are as follows: * Double acting cylinder * 3/2 push button valve © 3/2roller valve © Shuttle valve * 3/2 foot pedal actuated valve 5/3 pneumatic actuated direction control valve © Compressed air source and connecting piping Vishal Singh (00320903613) [35Figure 5.2 Magazine Ejection Mechanism According to the problem stated, upon actuation of either the push button of valve (S1) or the foot pedal valve (S2), a signal is generated at 1 or 1(3) side of the shuttle valve. The OR condition is met and the signal is passed to the control port 14 of the direction control valve (V2). Due to this signal, the left position of V2 is actuated and the flow of air starts. Pressure is applied on the piston side of the cylinder (A) and the gylinder extends. If the push button or pedal valve is released, the signal at the direction control valve (V2) port is reset. Since DCV (V2) is a double pilot valve, it has a memory function which doesn't allow switching of positions. As the piston reaches the rod end position, the roller valve (S3) is actuated and a signal is applied to port 12 of the DCV (V2). This causes actuation of right side of DCV (V2). Due to this actuation, the flow enters at the rod-end side of the cylinder, which pushes the piston towards left and thus the cylinder retracts. Vishal Singh ( 903613) |36References Boltan, W, Mechatronics: electronic control systems in mechanical and electrical engineering, Longman, Singapore, 1999 Boucher, T. ©, Computer automation in manufacturing - an Introduction, Chapman and Hall, 1996 Blackburn. F,G.Reethof, and J. L. Shearer, Fluid Power Control, New York: Technology Press of M. |. T. and Wiley Hasebrink J.P., and Kobler R., “Fundamentals of Pneumatics/electropeumatics”, FESTO Didactic publication No. 7301, Esslingen Germany, 1979.