P2

ELECTRO PNEUMATIC CONTROL

Moch Farchan Hasbullah

07 11 18 4000 0135

AJ.104 & B.105

Control & Industrial Automation Laboratory
Electrical Engineering Department
ELECTICS ITS
 P2
Electro Pneumatic Control

Faiz Ahmad Kurniawan

07 11 18 4000 0143

AJ.104 & B.105

Control & Industrial Automation Laboratory
Electrical Engineering Department
ELECTICS ITS
 P2
ELECTRO PNEUMATIC CONTROL

Nuriza Oktifamajjid F
07 11 18 4000 0145

AJ.104 & B.105

Control & Industrial Automation Laboratory
Electrical Engineering Department
ELECTICS ITS
 P1
DC Motor Speed Control System

Mohammad Irvan Wicaksono

07 11 18 4000 0181

AJ.104 & B.105

Control & Industrial Automation Laboratory
Electrical Engineering Department
ELECTICS ITS
 P2
Electro Pneumatic Control

Tito Bambang Priambodo

07 11 18 4000 0229

AJ.104 & B.105

Control & Industrial Automation Laboratory
Electrical Engineering Department
ELECTICS ITS
 BASIC THEORY
Pneumatic comes from the Greek which means air or wind. All systems that use stored energy
in the form of compressed air to produce work are called pneumatic systems. In the past,
humans used compressed air for various limited purposes, such as increasing the wind for car
tires, etc. Actually, the use of compressed air can still be developed for various purposes, such
as the production process, for example, mechanical movements, which have been carried out
by human workers. Mechanical movements can also be performed by pneumatic components
such as pneumatic cylinders, pneumatic motors, pneumatic robots, etc. The combination of
mechanical movements by Pneumatic actuators can be integrated into mechanical movements
for the purposes of a continuous and flexible production process. To explore the use, and how
the pneumatic automation system works. Provide examples of applications for the use of a
simple and real pneumatic automation system. Discusses the design of a pneumatic system
using software chosen because of its wide use in the industrial world and in everyday life To
make it easier Planning and Clarifying the scope of the author's problem. Limiting the
discussion to the simulation. Designing a pneumatic system. The objectives of preparing the
report are: To know the work of a Pneumatic system and to know the briquette pressing process,
Know the function of the existing Pneumatic components, both in the symbols listed on each
component and in the Motion circuit system Able to understand, make Design and calculation
of Pneumatic systems , To broaden the students' knowledge regarding matters related to
appropriate technology. Pneumatics is always related to the technique of using compressed air,
both pressure above 1 atmosphere and pressure below 1 atmosphere (vacuum). Peneumatik Is
the science of all processes of the mechanism in which air moves a force or movement. The
equation in use is air as a working fluid. The air on the earth's surface consists of a mixture of
various gases, the composition of these gases includes 78% oxygen, 21% nitrogen, 1% other
gases such as carbon dioxide etc. In the pneumatic system, the air functions as a transfer
medium and as a storage of energy (power) by pressing or compressing it. The pressure or
power provided for Pneumatic work, namely 2 to 15 bars, can also work under 1 atmosphere
(vacuum). In addition to considering the pneumatic motion system, there are several
advantages and disadvantages that need to be considered, including :
1. Pneumatic Advantages : Easy to get fluids Air everywhere is available with an infinite
amount of used air generated from the process Emphasis on pneumatics can be
removed freely, clean and dry Compressed air is clean and dry So if a leak occurs in
the pipeline it will not pollute the environment around pipes that occur Leaks, are not
sensitive to temperature So the air that is used is completely clean so that it can be used
both At high and low temperatures, compressed air can also be used in very hot places,
Safe against fire and explosion Work safety and the large production of Compressed
Air does not pose a fire or explosion hazard
2. Pneumatic Losses: Limited compressive force Compressed air can generate only a
limited force For large forces At a pressure can be in.
3. Network and required piston diameter Large high energy costs: The cost of producing
compressed air is high Therefore for production and distribution Special equipment is
needed, creating sound can Air blown out causes noise, especially in work spaces
which is very disturbing After knowing the advantages and disadvantages and
effectiveness of pneumatics, the next thing that needs to be known is in the pneumatic
system, namely pneumatic It consists of a series of several components:
• Acumulators, Acumulators or working cylinders are pneumatic equipment that
performs direct work. Linear motion accumulators consist of several types, namely
single acting and double acting
 • Solenoid control valve, control valve functions to regulate the direction of the
compressed air that will work to move the aquater. There are several types of solenoid
valve, giving the name of each type based on the number of holes (ports), the number
of working positions, the type of valve actuator and other additional names according
to the characteristics of the valve. Types of solenoid valves such as 2/2, 3/2, 4 / 2, and
5/2
• Compressor, the compressor has a function to generate compressed air by sucking
and compressing the air and then stored in the air tank until the air reaches the required
pressure.
• Air service unit, a compressed air acquisition unit, compressed air that will enter in a
pneumatic system must meet requirements such as not containing dust, low water
content, containing lubricants, this is intended as a treatment for pneumatic
components.
Supporting components for Air service units include:
A. Air filter Serves as an air filter tool taken from outside air which still contains lots
of dirt. The filter serves to separate carried particles such as dust etc.
B. Air tank, serves to store compressed air up to a certain pressure until the filling
stops, then it can be used whenever needed
C. Air dryer Serves to dry the air containing water so as not to damage the pneumatic
components
D. Lubricating tubes Pneumatic system components require lubrication so they don't
wear out quickly, and can reduce heat caused by friction. Therefore compressed /
compressed air must be
E. Contains a grease mist obtained from the lubricant tube on the regulator.
F. Compressed air regulator Air that has met the requirements will then be distributed
as needed. To regulate the size of the incoming air, an air tap is needed on the
regulator, so that the air supplied is in accordance with the work requirements
G. Conductors and Connectors, Conductors and connectors are components that
distribute compressed air to the pneumatic support components up to the aquatic
so that they become one pneumatic circuit.
In its application, the pneumatic system is widely used as an automation system. Pneumatic
System Components The pneumatic system consists of several levels that reflect the hardware
and signal flow. Several levels form a control path for the signal flow from the input signal to
the output signal. Medium pressure pneumatic systems have a pressure range between 100 -
150 Psi, usually don't use air tubes. This system generally takes compressed air directly from
the compressor motor. Low air pressure is obtained from the Vane type air pump. Thus, the
air pump releases air pressure continuously with a pressure of 1–10 Psi. to the Pneumatic
system. The condition of the air in the atmosphere is influenced by temperature and pressure.
The function of the Oil and Water Trap is to separate oil and water from the air entering the
compressor. The percentage of water is very small in the air that enters the pneumatic system,
but it can be a serious cause of system malfunction. The dehydrator has a function as this unit
is a chemical separator to separate the remaining moisture which may be left behind when the
air passes through the Oil and Water unit. Trap. After the compressed air passes through the
Oil and Water Trap unit and the Dehydrator unit, finally the compressed air will pass through
the filter to separate the air from the possibility of dust and dirt which may be in the air.
Pressure Regulator is a system of air pressure ready to enter at high pressure increases pressure
in the chamber and forces the load on the piston. Restrictor is a type of valve controller used
in pneumatic systems. There are two (2) types of restrictor commonly used, namely the Orifice
type and the Variable Restrictor.
 PRE-EXPERIMENT TASK
1. What is the different beetween pneumatic and hydraulic system?
Pneumatic of pneumatic is taking compressed air adventage to make translation move in
a piston. Work principle of pneumatic is use aeromechanical law that consider balance of
gas and steam with outside work (aerostatic) and aerodynamic. system is a technology in
engineering that use compressed air to create mechanical effect. Basic theory
Hydraulic system is a technology in engineering that use pressurized liquids as a power in
a mechanism tool to control, give and utilize a power with pressurized liquids. Basic
theory of hydraulic is a liquid in a system with pressure in one side and different large in
both. We have notice that reverse comparison of a work and large of pressure. The
pressure push a pistin in another side of system. Work principle of hydraulic system is
Pascal law, “Pressure applied to an enclosed fluid will be transmitted without a change in
magnitude to every point of the fluid and to the walls of the container. The pressure at any
point in the fluid is equal in all direction”.
2. How do the 3/2-way valve and 5/2-way valve works?
Difference of a control valve can be notice by the name of its valve. Example, we take
a/b-way valve. “a” is port number, and “b” is position number. “a” count of pressurized
air hole in a valve, and “b” count of valve work position.
3/2-way valve mean it have 3 air chanel and 2 work position. In first work time of 3/2-
way valve, pressurized air from a cylinder go out from chanel 2 to chanel 3. Meanwhile,
pressurized air from compressor stand by in chanel 1. If 3/1-way valve receive control
signal (solenoid) form left, then work position change to left box and pressurized air form
compressor will flow to solenoid.
5/2-way valve mean it have 5 air chanel and 2 work position. First, pressurized air from
compressor will flow from first chanel to second chanel, meanwhile pressurized air from
cylinder go out from 4th to 5th chanel. If 5/2 valve receive a signal control from left an
pressurized air from compressor will flow from first chanel to 4th chanel. Pressurized air
form cylinder will go out from second chanel to 3rd chanel.
3. Explain how the components in Fluid Sim work or are used below:
- Single acting cylinder and double acting cylinder
Single acting cylinder needs a single supply of pressurized air to make the cylinder
move. In Single acting cylinder, to make the cylinder back in first position needs a
spring.
Double acting cylinder needs a double supply of pressurized air to make the cylinder
move. When the supply come form left, then the cylinder move to right. When the
supply come form right, then the cylinder move to left.
- Make switch and break switch
Make switch is kind of pressure switch with 2 node terminal contact NC (normally
close). Break switch is kind of pressure switch with 2 node terminal contact NO
(normally open)
- 3/2-way valve Normally Closed (N.C) and 3/2-way valve Normally Open (N.O)
3/2 valve NC work if current flow to solenoid, so there is an electromagnet can cause
the armature move, and then pressurized air flow from inlet to outlet, meanwhile the
solenoid is closed. If in solenoid have no current, then electromagnet in solenoid is
dissapeared. It causes inlet is closed and air in outler will through the solenoid chanel
then solenoid is open. 3/2 valve NO work if no current flow to solenoid, so there is an
electromagnet can cause the armature move, and then pressurized air flow from inlet
to outlet, meanwhile the solenoid is closed. If in solenoid have current, then
electromagnet in solenoid is dissapeared. It causes inlet is closed and air in outler will
through the solenoid chanel then solenoid is open.
 EXPERIMENT 1 DATA
Valve Type
Normally Open Normally Closed
Depressed Retract Extend
Condition
Released Extend Retract

EXPERIMENT 2 DATA
Normally Open Normally Closed Cylinder Condition
0 0 Retract
0 1 Retract
AND
1 0 Extend
1 1 Retract
0 0 Extend
0 1 Retract
OR
1 0 Extend
1 1 Extend

EXPERIMENT 3 DATA
Roller Lever Type
Left Right
Depressed Retract Extend
Condition
Released Extend Retract

EXPERIMENT 4 DATA
Cylinder
Function PB1 PB2 Indicator Light
Condition
Depressed Released On Extend
Depressed Depressed On Extend
OR
Released Released Off Retract
Released Depressed On Extend
Depressed Released Off Retract
Depressed Depressed On Extend
AND
Released Released Off Retract
Released Depressed Off Retract

FINAL EXPERIMENT DATA

Indicator Light Cylinder Condition
PB1 PB2 Single Double
L1 L2 L3 L4
Acting Acting
Depressed Released off off on on Extend Retract
Depressed Depressed off off on on Extend Retract
Released Released off off on on Extend Retract
Released Depressed on on off off Retract Extend
 ANALYSIS DATA
First condition of experiment is PB1 depressed and PB2 released. In the fluidsim simulation,
we get L1 off, L2 off, L3 on, L4 on, single acting cylinder extend, and double acting cylinder
retract. L1 off because when PB1 depressed, electric through relay K1 then make switch in
rung 3 close, electric through solenoid Y2 make double acting cylinder retract. Its retract
contact LS1, and brake switch LS1 in rung 5 open. L2 off because double acting cylinder does
not extend and LS2 does not contact. L3 on because LS1 contact with piston of double acting
cylinder. L4 on because make switch LS2 in rung 9 close (does not contact with piston of
double acting cylinder). Single acting cylinder extend because brake switch LS2 in rung 7
closed and contact relay Y3.
Second condition of experiment is PB1 depressed and PB2 depressed. In the fluidsim
simulation, we get L1 off, L2 off, L3 on, L4 on, single acting cylinder extend, and double acting
cylinder retract. When PB2 depressed, it contact relay K2 then make switch K2 in rung 4 close
and contact relay Y1. Double acting cylinder does not extend because relay Y2 is contact too.
The resul is the same way with first condition. L1 off because when PB1 depressed, electric
through relay K1 then make switch in rung 3 close, electric through solenoid Y2 make double
acting cylinder retract. Its retract contact LS1, and brake switch LS1 in rung 5 open. L2 off
because double acting cylinder does not extend and LS2 does not contact. L3 on because LS1
contact with piston of double acting cylinder. L4 on because make switch LS2 in rung 9 close
(does not contact with piston of double acting cylinder). Single acting cylinder extend because
brake switch LS2 in rung 7 closed and contact relay Y3.
Third condition of experiment is PB1 released and PB2 released. In the fluidsim simulation,
we get L1 off, L2 off, L3 on, L4 on, single acting cylinder extend, and double acting cylinder
retract. Double acting cylinder first position is 1. When we play the simulation, air pressure
through retract way of double acting cylinder and make LS1 in distance rule contact. LS1
contact cause brake switch LS1 in rung 5 is open (L1 off), and make switch LS1 in rung 8 close
(L3 on). L2 and L4 are off because duble acting cylinder piston does not contact LS2 in distance
rule. Single acting cylinder is extend because brake switch LS2 in rung 7 open and contact
relay Y3 (air pressure through the cylinder make the cylinder extend).
Fourth condition of experiment is PB1 released and PB2 depressed. In the fluidsim simulation,
we get L1 on, L2 on, L3 off, L4 off, single acting cylinder retract, and double acting cylinder
extend. When we push PB2, electric through relay K2 then make switch K2 in rung 4 close
and relay Y1 contact. When Y1 contact,it make double acting cylinder is extend and contact
LS2 in distance rule. When LS2 contact, it make brake switch LS2 in rung 7 is open and relay
Y3 does not contact. This make single acting cylinder is retract (no air pressure through the
cylinder). L1 on because brake switch LS1 close (does not contact with double acting piston).
L2 on because make switch LS2 is close (double acting piston contact LS2 in distance rule).
L3 off because LS1 in distance rule does not contact and make switch in rung 8 is open (L3
off). L4 off because LS2 in distance rule contact and brake switch LS2 in rung 9 is open (L4
off).
 EXPERIMENTAL ANALYSIS
1. Explain why we need Pressure Control Unit for this experiment and explain each of
component function!
We need pressure control unit in this experiment because we need to control pressure which
go to cylinder.
Air service unit function is to control air pressure in pneumatic system, avoid corrosion,
dust and water that damage components in pneumatic system.
Compressed air supply function is to supply air pressure in system
5/2 valve with selection switch have 5 air chanel and 2 work position. First, pressurized air
from compressor will flow from first chanel to second chanel, meanwhile pressurized air
from cylinder go out from 4th to 5th chanel. If 5/2 valve receive a signal control from left an
pressurized air from compressor will flow from first chanel to 4 th chanel. Pressurized air
form cylinder will go out from second chanel to 3rd chanel.
3/2-way valve with pushbutton have 3 air chanel and 2 work position. In first work time of
3/2-way valve, pressurized air from a cylinder go out from chanel 2 to chanel 3. Meanwhile,
pressurized air from compressor stand by in chanel 1. If 3/1-way valve receive control signal
(solenoid) form left, then work position change to left box and pressurized air form
compressor will flow to solenoid.
Double acting cylinder is cylinder with two air pressure input. It can retract with the first
air input and extend with another
Single acting cylinder is cylinder with one air pressure input. It can retract automatically
because it springs inside
Distance rule function is to measure the distance of cylinder
2. Explain how the whole system of the circuit works!
When we push the play button in fluidsim, the air pressure will through second channel of
5/2 valve and make double acting cylinder retract and through first channel of 3/2-way valve
and make single acting cylinder extend.
When we push PB1, it makes relay K1 on, make switch K1 in rung 3 depressed and air
through second channel of 5/2 valve (double acting cylinder retract). It retracts make LS1
in distance rule depressed (brake switch LS1 in rung 5 open L1 off, make switch LS1 in
rung 8 close and L3 on). L4 on because brake switch is normally closed.
When we push PB1 and PB2, it has the same way with when we just push PB1.
When we just push PB2, it makes relay K2 on, make switch K2 in rung 4 depressed and air
through first channel of 5/2 valve (double acting cylinder extend). It extends make LS2 in
distance rule depressed (make switch in rung 6 depressed L2 on, and brake switch in rung
7 is open make single cylinder have no pressure). L1 on because brake switch is normally
closed.
3. Look for an application of electro-pneumatic in the industry and describe it briefly!
Electro pneumatic application in the industry can be categorized into two types, large scale
and small scale. Large scale applications of electro pneumatic system are in aerospace
exploration and aeronautical engineering. Electro pneumatic is necessary to pressurize body
of a passenger plane or a rocket. Submarine cabins are pressurized and depressurized to sea
level with help of electro pneumatics too.
In small scale applications in the industry, electro pneumatic can be used in nail gun,
jackhammer, air brakes, industrial conveyors, etc. In nail gun, air from a compressor is
stored in a chamber. The piston ejects the nails when trigger is pulled because pressure from
nail gun chamber. In jackhammer, external compressor is connected and deliver force which
make tools forces up and down. In air brakes, it used in truck and buses. Compressed air
make it slow down. In industrial conveyor, electro pneumatic is used to divert containers or
packages that are not properly filled.
 ATTACHMENT
1. a) Normally Open
Depressed

Released
b) Normally Closed
Depressed

Released
2. AND Logic Parallel
OR Logic Parallel
3. Roller Lever Left
Roller Lever Right
4. Direct control single acting cylinder using relay control
OR Logic
AND Logic
5. Final Experiment (Application of Electro-Pneumatic)
 ASSISTANT TASK
Study Case
1. There are 2 cylinders, A and B
2. Cylinder A and B are double acting
3. It uses electro-pneumatic system
4. The input consists of 1 push button as a start button when pushed and end button when
it released
5. If the push button is press, the system enters the start stage and cylinder A and B move
with a sequence of A+; A-; B+; and B-
6. (+) means extend, (-) means retract, (;) means sequential
7. The system works in continuous stage when the start button is push.
Answer :
 SUMMARY
Pneumatic is a device that use compressed air to work. Pneumatic uses 3 types of control,
manual control, mechanical control, and electro control. However, the compressed air pressure
cannot be regulated by the compressor tank. So, the external device called air service unit is
used to control the pressure of compressed air.
1. Manual Control
As the name suggest, manual control works by our hands controlling the input of pneumatic
system. By pressing the valve input, the output valve can be either open or closed depends
whether the it is normally open (NO) valve or normally closed (NC) valve. If the valve is
normally closed, by pressing the input, it will release the compressed air from the compressor
and drive the pneumatic cylinder to extend. If the valve is normally open, by pressing the input,
it will close the air flow from the compressor tank and drive the pneumatic cylinder to retract.
2. Mechanical Control
This type of control uses a roller lever to work. Roller lever is a mechanical device in which
its working mechanism is by detecting the movement of the roller to activate the input of the
valve
3. Electro control
Electro control use electricity to control the valve. Electro control use relay, solenoid, and
switch.
All control system either manual or mechanical or electro control are able to form logic gates
AND and OR.