Professional Documents
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Book
. . . . .
WELCOME TO THE PNEU BOOK
INTRODUCTION
he Pneu Book is produced by SMC Pneumatics
(UK) Ltd and is available to all those with an
interest in the theory, development and
application of pneumatics technology.
SIZING PNEUMATIC
INTRODUCTION
VALVES & CYLINDERS
A GUIDE TO
TERMINOLOGY
AIR PREPARATION
PNEUMATIC VALVE
TECHNOLOGY
VACUUM
TECHNOLOGY
PNEUMATIC ACTUATOR
TECHNOLOGY
SOLENOID VALVES
RODLESS CYLINDERS
INTELLIGENT ACTUATORS
SIZING PNEUMATIC VALVES
AND CYLINDERS
Cylinder Sizing
Cylinder applications can be categorised as either:
1A.1
Cylinder Thrust
Cylinder thrust is a function of:
Piston diameter
VALVES & CYLINDERS
1A.2
seals is considered to be 80% whilst more sophisticated and
technologically advanced designs can be as high as 97%.
1A.3
For the extending stroke on a single acting cylinder:
FE = P x A x m - FS
VALVES & CYLINDERS
SIZING PNEUMATIC
Where:
FE represents the extending cylinder thrust
P = available pressure
A = piston area
m = efficiency
Fs = the spring force at the end of stroke
FR = p(D2 - d2)/4 x P x m
Where:
FR represents the cylinder thrust to retract
D = piston diameter
d = piston rod diameter
P = available pressure
m = efficiency
1A.4
Transposed to give:
D2 = (4 x 1600)/(600000 x p x 0.9)
D = Ï0w.0
w0w3w8
w m = 0.0614 m
D = 61.4 mm
Figure 1A.1
This chart does not take cylinder efficiency into consideration since
this will vary between manufacturers.
1A.5
The graph below, Figure 1A.2, allows an efficiency factor (m)
to be obtained for various cylinder bore sizes where the
supply pressure is known.
VALVES & CYLINDERS
SIZING PNEUMATIC
EFFICIENCY
1.00
Ø 100
Ø 50
Ø 20
Ø 100
0.90
Ø 50
Note 0
Ø1
Friction µ
1 2 3 4 5 6 7 8 9 10
Supply Pressure bar
Figure 1A.2
1A.6
Air Consumption and Air Flow
6000 ln/min.
1A.7
System Sizing
Traditionally, valves have been specified by matching their
port size to that of the cylinder in use. Also, tube fittings and
tube are often selected by appearance rather than
VALVES & CYLINDERS
SIZING PNEUMATIC
Cv Value kv S
(ln/min. system) (effective sectional area-mm2)
1 14.3 18
1.2 17.1 21.6
1.17 16.7 21.0
0.070 1 1.26
0.0556 0.793 1
1A.8
For each case, a formula is available to calculate the air flow
under given conditions of pressure.
wp
For cv: Q = 400 x Cv x Ï[(ww2w +w.0
1w3
ww3w) x Dp] x Ï[2
w73
w/( w27
w3 ww+w)]
nw
SIZING PNEUMATIC
For S: Q = 22.2 x S x Ï[(
wp
ww
2w +w.0
1w33
w)w x Dp] x Ï[2w73
w/(w27
w3 ww +w)]
nw
w7
Ï[2 ww3w2
/(ww7w3w
+w)]
nw is so close to 1 that this part of the formulae
can be ignored.
1A.9
In our example:
p x 6 32 cm x 20 cm / 4
= 624 cm3
or 0.624 litres.
V2 = 7.85 x 0.624/ 1
therefore,
air consumption = 4.9 ln/stroke
1A.10
In order that this value can be used in our formula (Q), it
must be expressed in ln/min.
Q = 4.9 x 60
w2ww
Q = 400 x Cv x Ï(p +w.0
1w3w3w)w x Dp
w2ww
Cv = Q/[400 x Ï(p +w.0
1w3w3w)w x Dp]
therefore,
w6w.8
Cv = 294/[400 x Ï(6 w5ww
+w.O
1w3w3ww
xw.4
0w5w]w
= 0.39
1A.11
Applying System Cv to Component Selection
Individual components within a system each have a Cv
value, i.e. valves, tube fittings, and tubing.
VALVES & CYLINDERS
SIZING PNEUMATIC
where Cv1 & Cv2 have the same value (50:50 split).
1 = 2/Cv2
so, Cv2 = 2
w
hence Cv = Ï2
= 1.4
Having selected the valve, its port size will determine the
largest tube size that can be used (dependent on the range
of tube fittings available).
With this size of port, tube fittings determine that the maximum
SIZING PNEUMATIC
If our system consists of 2 metres of 10 mm tube, three
10mm O/D x 1/8” BSP straight adaptors and one 10mm O/D
x 3/8” BSP elbow adaptor; tube and fittings Cv would be:
O/D I/D Cv =
ø4 mm ø2.5 mm Cv = 0.11/ÏLw
ø6 mm ø4 mm Cv = 0.39/ÏLw
ø8 mm ø6 mm Cv= 1.14/ÏLw
ø10 mm ø7.5 mm Cv= 2.07/ÏLw
ø12 mm ø9 mm Cv= 3.36/ÏLw
ø16 mm ø13 mm Cv = 8.91/ÏLw
1A.13
Continuing our example:
Tube
3 off 10mm O/D - 1/8” BSP straight adaptor
therefore,
Cv= Ï1 w/1
w.2w9w
= 0.88
1A.14
A GUIDE TO TERMINOLOGY
Pneumatics, in common with most advanced technologies,
has its own vocabulary which, even to those who have spent
years in the industry, can be both confusing and, at times,
TERMINOLOGY
A GUIDE TO
difficult to remember.
Pneumatic Terminology
Actuator
A device for converting the energy of compressed air into
work. The term is generally applied to cylinders.
Aftercooler
A device for cooling compressed air as it leaves the
compressor, to prevent excessive condensation occurring
further downstream.
Air Chuck
Commonly called grippers; pneumatically powered jaws are
used to grip a workpiece - typically used for pick and place
applications.
Automatic Drain
Designed to be installed at strategic points throughout the
pneumatic system, to allow condensate to be automatically
removed.
1B.1
Bar
Standard measurement of pressure. One bar is approximately
equal to atmospheric pressure.
Bore Size
TERMINOLOGY
Boyles law
At a constant temperature, the volume of a given quantity of
any gas is inversely proportional to the pressure upon the
gas; i.e. V is proportional to 1/P, or PV = a constant. True for
a perfect gas. Named after Robert Boyle, (1627-1691).
Cv
A Cv of one is equal to a flow rate of one US gallon of water
per minute, with a pressure drop of one psi.
Cascade
A type of pneumatic circuit designed to overcome the problems
associated with trapped pressure signals.
Check Valve
A device which allows compressed air to pass through in
one direction, but prevents it returning along the same path.
SEE NON-RETURN VALVE
Compressor
A machine for compressing atmospheric air so that it can be
used to drive pneumatic devices. SEE RECIPROCATING AND
ROTARY COMPRESSORS.
Cushioning
A facility available on actuators to cushion at the end of
1B.2
stroke to prevent sudden impact.
Cylinder
A linear-actuator.
TERMINOLOGY
Dew Point
A GUIDE TO
The temperature at which the water vapour present in air
saturates the air and begins to condense, i.e. dew begins to
form.
F.R.L.
Air preparation unit consisting of Filter, Regulator, and
Lubricator.
Filter
A device for removing contaminants from compressed air,
typically moisture, oil and solid particles.
Flow
The flow of air through a pneumatic system. Expressed in
normal litres per minute, ln/min., never as NL/min.
kv
A kv of one is equal to a flow rate of one litre of water per
minute, with a pressure drop of one bar.
Manifold
A device which is capable of dividing a single compressed
air source into several outlets. The most common application
is for supplying air to a number of valves secured to a
common mounting base, i.e. a valve manifold.
1B.3
Newton
The derived SI unit of force. The forced required to give a
mass of one kilogram an acceleration of one metre per
second per second. Symbol N. Named after Sir Isaac Newton
(1642-1727).
TERMINOLOGY
A GUIDE TO
Pascal
The derived SI unit of pressure, equal to 1 newton per
square metre. Symbol Pa. (100,000 Pa = l kgf/m2). Named
after Blaise Pascal (1623-1662).
Poppet Valve
A type of valve construction whereby sealing is achieved by
means of a flat seal against an orifice.
Reciprocating Compressor
A compressor in which air is pressurised by means of piston
and cylinder.
Regulator
A device for adjusting the pressure of compressed air,
typically used to reduce available pressure to a suitable
working pressure.
Relative Humidity
The ratio of the pressure of the water vapour actually
present in the atmosphere to the pressure of the vapour
which would be present if the vapour were saturated at the
same temperature.
Ring Main
A term used to describe a compressed air piping system
1B.4 which is arranged in a complete loop, i.e. a ring.
Rodless Cylinder
A cylinder whose moving element actuates within the length
of the cylinder body and does not use a conventional
extending piston rod. Space saving is therefore achieved.
TERMINOLOGY
Rotary Compressor
A GUIDE TO
A compressor which uses rotating vanes or meshing screws
to pressurise air.
Slide Unit
A precise linear actuator which uses a guide mechanism to
improve accuracy of travel and/or provide a facility to limit
rotation about its axis of travel.
Slide Valve
Directional control valve where sealing is achieved by
sliding a lapped metal seal across the valve’s orifices.
Solenoid Valve
A valve which is activated with the use of an electrically
operated solenoid.
Speed Controller
A steplessly variable orifice for varying the flow of
compressed air thus providing a speed control facility for
actuators.
1B.5
Electronics Terminology
EEPROM or E2PROM
Electronically Erasable Programmable Read Only Memory.
A ROM chip (see below) which can be electronically erased.
TERMINOLOGY
A GUIDE TO
I/0
Input/Output. A statement of the number of inputs and
outputs for a specific device or system.
Ladder logic
Complex programming language used for configuring PLC’s
(see below).
PID
Process Integer Derivative
PLC
Programmable Logic Controller. Sometimes called Programmable
Controller. Designed to control the sequencing of electronic
equipment.
RAM
Random Access Memory. A memory chip which is used to
provide working space for operations in progress at any
one time.
ROM
Read Only Memory. A memory chip which, once written
to, cannot be erased. Used to store set parameters.
1B.6
AIR PREPARATION
AIR PREPARATION
devices. Correct air preparation will minimise the
risk of component failure, increase their life span and reduce
energy consumption.
Air Contamination
Airborne contamination is the most common problem with
compressed air systems. Contaminants include particulate
matter, moisture and unwanted oils. These can be drawn in
from the surrounding atmosphere or physically injected into
the system, either by the compressor or by human error; it
is not unknown for lubricating oils to be added to non-lube
systems.
air, (50% of these particles are less than 2mm in size). Ref. Institute of
Mechanical Engineers
Compress this to 7 bar and the density will exceed 1100 paper no. C390/021.
million particles per cubic metre.
2A.1
and gradually accumulate on both static and moving surfaces
within pneumatic equipment, causing valves to stick, seals
and other components to wear and, ultimately, devices to
fail.
AIR PREPARATION
2A.2
surrounding environment. Left untreated, these will attack
rubber and plastic seals and gaskets, corrode air lines and
generally contribute to a steady decline in operating
efficiency.
AIR PREPARATION
The Solution
Although filters can be fitted to the compressor intake, it is
difficult to prevent contaminants under 2-5 microns being
drawn in; certainly it is almost impossible to eliminate water
vapour and surplus compressor oil being injected into the air
supply. Instead, it is necessary to incorporate filtration,
drying and pressure regulation equipment downstream of
the compressor. Additionally, lubrication units may be
required prior to some pneumatic devices.
Filtration
A typical separator unit operates by directing inlet air at high
speed over a louvred deflector plate; this creates a vortex
where solid particles and moisture droplets are centrifugally
spun out of the air stream. Liquid and solid matter in
solution then collects at the base of the filter, where it can
be drained off.
2A.3
speed through the fibres of the element eventually coalesce,
forming a film which adheres to the filter. Depending on the
materials used within the element and the number of layers,
it is possible to remove particles down to 0.01 micron in size,
which typically represents 99.99% of all contaminants.
AIR PREPARATION
3 Humidity to atmospheric Where removal of humidity Similar to (1) but as the air is
dew point of -17˚C. is imperative but traces of dry additional general
Further as in (1). fine dust and oil are spray painting.
acceptable.
6 As (5) with additional odour Where absolutely pure air, Pharmacy, food industry for
removal. as under (5), but odour free. packaging, air transport,
brewing and breathing air.
AIR PREPARATION
internal and external components; carbon impregnated
elements are also available for use in systems where odours
must be removed.
Dehydration
Most compressors are fitted with an aftercooler. This is
designed to remove a large proportion of the condensate
resulting from the compression process, by reducing the air
temperature to within 10-15 °C of the ambient temperature.
2A.5
To reduce the level of water vapour still further, especially if
parts of the pneumatic system are exposed to areas where
temperatures fluctuate, such as where pipes are routed along
outside walls or through ceiling areas, it is necessary to
incorporate drying systems. These are generally absorption
AIR PREPARATION
Refrigeration +3˚C PDP best possible dew point. Output: dew point will vary with
approach temperature at the
Input temperatures can be as high inlet, and cleanliness of heat
as 60˚C. (Aftercooler preferred- exchanger.
will remove bulk moisture and suit
sites with no low temperatures on
outside pipework.)
Figure 2A.2
2A.6
An important point to note is that if adsorption or
absorption dryers are used, it is essential to incorporate fine
micro-filters, to prevent any residue from the chemicals
being carried into the pneumatic system as a fine mist.
AIR PREPARATION
Regulation
Pressure regulation is necessary to maintain a consistent
operating pressure. If this is too great, energy costs will be
unnecessarily high. Too low a pressure and the system will
be incapable of supporting the work loads required.
Pressure regulators function by means of a piston or
diaphragm acting against a spring. Thus, output pressures
are controlled. Combined regulator and filter units are also
available .
Lubrication
The majority of modern pneumatic devices are now
pre-lubricated and require no additional lubrication. Older
equipment, however, does require internal lubrication, by
adding a suitable oil to the compressed air. This technique,
however, results in increased maintenance and can lead to
the presence of vaporised oil in exhaust outlets.
Points to Consider
The design of air preparation devices should be such that
they are easy to install and maintain. Similarly, they should
provide an efficient throughput of air, ensuring that
contaminants are effectively removed, while pressure losses
are reduced to an acceptable level.
2A.7
air preparation and other equipment, such as valves and
actuators, function efficiently.
2A.8
Dew Point and
Relative Humidity
RELATIVE HUMIDITY
A
The terms which are most often applied in this context are
dew point and relative humidity.
Dew Point
The amount of water vapour contained in air is directly
proportional to its temperature, not, as is commonly
supposed, to its pressure.
2B.1
used as this is the most common compressed air system
pressure in general use.
Temperature ˚C 0 5 10 15 20 25 30 35 40
g/m3n (atmospheric) 4.98 6.99 9.86 13.76 18.99 25.94 35.12 47.19 63.3
g/m3 (pressure) 4.98 6.86 9.51 13.04 17.69 23.76 31.64 41.83 54.108
Figure 2B.1
2B.2
Relative Humidity
Relative Humidity (RH) is the ratio between the actual water
vapour content of a volume of air to the maximum water
RELATIVE HUMIDITY
vapour content at a given temperature.
Note
This graph is intended
as a guide only.
Note
The bold line refers to
atmospheric air with
the volume at the
temperature in question.
Figure 2B.2
2B.3
For the UK, assuming an average humidity of 65%, the
compressor would, therefore, draw in 11g of moisture with
each lm3 of air. This would equate to the following:
RELATIVE HUMIDITY
DEW POINT AND
The following are the three main types of compressed air
drying equipment:
Deliquescent
Refrigerant
Desiccant
2B.5
PNEUMATIC VALVE
TECHNOLOGY
PNEUMATIC VALVE
Valves are essential components in every pneumatic system,
TECHNOLOGY
providing a method by which the air flow to or from other
devices can be accurately controlled. The following chapter
looks at the types of valve that are available and explains the
differences between the various techniques employed to
improve performance and reliability.
Basic Requirements
Before considering the different types of valve, it is
important to understand the basic operational specification
that every valve should meet. In general terms these are as
follows:
3.1
Valve Types
There are two main types of valve: poppet and spool. These
can be further classified by the method of actuation:
mechanical or air pilot and solenoid.
PNEUMATIC VALVE
TECHNOLOGY
Poppet Valves
Poppet valves incorporate a manual or mechanically operated
plunger, which is normally held in the closed position by a
spring or by air pressure. Depressing the plunger opens the
valve and allows air to flow. A seal is achieved between the
plunger and the valve seal by means of flat discs and washers,
O-rings or spherical closures.
3.2
Spool Valves
In essence, a spool valve uses a specially profiled rod or
spool, sliding longitudinally within the centre of the valve, to
switch the air flow between different inlet and outlet ports.
The direction of air flow is at right angles to that of the spool.
PNEUMATIC VALVE
TECHNOLOGY
The spool can be moved manually or by means of an air
pilot or electrically operated solenoid.
Spool Design
The spool slides within the barrel of the valve. Cut into the
barrel are the various port openings, with the machined
profile of the spool providing flow paths across different
ports, depending on the position of the spool. The critical
factors affecting valve performance are therefore as follows:
i) Friction between the spool and the barrel.
ii) The force required to move the spool.
iii) The leakage of air around the spool. In particular,
at the point where the spool seals each port opening.
iv) The affect of contamination.
3.3
O-ring Spools
Traditionally, spools have been manufactured from crimped
stainless steel or turned aluminium, with nitrile rubber O-
rings either being fitted into grooves on the spool, with
spacers added to keep them in position, or within plastic or
PNEUMATIC VALVE
TECHNOLOGY
3.4
As the O-ring is contained on three sides, by the body of
the valve and by spacers, changes in temperature or
contamination can also affect its efficiency. The O-ring can
either expand, leading to an increase in stiction, or contract,
resulting in leakage.
PNEUMATIC VALVE
TECHNOLOGY
Continuous operation at very low temperatures will also
cause the seal to become hard. The physical characteristics
of the rubber will similarly deteriorate if there are
contaminants, such as compressor oil, within the air system.
3.5
There is only a small number of moving parts, so reliability
is considerably improved. In addition, the elastomer is
thinly coated, by applying it the spool and allowing it to set,
before it is frozen and ground to match the valve body.
Dimensional changes, due to fluctuations in temperature or
PNEUMATIC VALVE
3.6
Stainless Match Ground Spool
and Sleeve Valve
Valves incorporating an all-metal match-ground spool, set
PNEUMATIC VALVE
within a sleeve, provide an operating life in excess
TECHNOLOGY
of 100 million cycles. Perhaps as importantly, they have
exceptionally short spool travel and require minimal force to
move the spool. This allows direct solenoid actuation, with
power consumption as low as 1.8 Watts.
3.7
Q Seals
To reduce the wear characteristics of both O-ring seals and,
to a lesser extent, bonded spool devices, a further design of
seal is also available.
PNEUMATIC VALVE
TECHNOLOGY
3.8
Methods of Actuation
Valves can be operated manually, mechanically or by means
of a solenoid or an air signal.
PNEUMATIC VALVE
TECHNOLOGY
two-position switch. Mechanical operators include cams or
roller levers.
3.9
Valve Selection
The changing face of industry in the UK has had a
considerable impact on the development of pneumatic
systems, especially that of control valves. The current
generation of equipment, in particular, is designed to meet
PNEUMATIC VALVE
TECHNOLOGY
3.10
VACUUM TECHNOLOGY
TECHNOLOGY
small electronic components to plate glass, or for holding
VACUUM
products in position, while other operations are carried out.
4.1
Vacuum ejectors have largely superseded the older
venturi-type generators and are constructed as shown in the
diagram below.
TECHNOLOGY
VACUUM
4.2
This phenomenon can, however, be utilised to produce
highly efficient two-stage vacuum ejectors, such as SMC’s ZM
devices.
TECHNOLOGY
VACUUM
The vacuum inlet is split between two chambers, the first of
which provides a high level of vacuum, while the second
increases the volume of air removed. By installing a check
valve between the two chambers it is therefore possible to
control the relationship between vacuum and flow, with the
valve closing as the vacuum increases or as the flow rate
falls. In addition, air consumption is minimised, as the
flow rate can be reduced once the vacuum has been applied
to the work piece.
4.3
Vacuum Pads
Having developed a vacuum or, to be more specific, a
suction force, it is then necessary to create a seal between
the ejector and the workpiece, so that it may be moved or
secured. This is generally achieved using vacuum or suction
TECHNOLOGY
The size and type of vacuum pad required for a given task
depends on a variety of factors, of which the most important
are the weight, surface finish and shape of the work piece.
In addition, however, the ability of the pad to retain an
optimum profile as the vacuum is applied, will also have a
direct impact on the performance of the system.
4.4
The solution is both to use relatively soft, ribbed pads,
capable of retaining the maximum volume of chamber
between the pad and workpiece, and to ensure that the
devices used to create the vacuum are also capable of
generating a high rate of flow. This draws the pad down
rapidly onto the work surface before a significant leakage
TECHNOLOGY
VACUUM
flow is set up. Two stage ejectors are ideal for this purpose.
Rough surface finishes will cause air to bleed under the rim
of vacuum pads. To overcome this it is necessary to increase
the level of vacuum applied and to use pads with smaller
diameters, to minimise the air loss. Larger numbers of pads
will, therefore, be necessary to retain the same overall pad
contact area. With deeply textured surfaces a softer pad
material will also reduce air loss, as the pad will mould itself
to the contours of the surface; a softer material can,
however, affect the level of grip which is achieved, as the
pad is likely to deform under pressure.
4.5
Lift Force
Tables showing the lift force available from different sized
ejectors are available from vacuum equipment manufacturers.
One point which should be remembered, however, is that
the figures supplied do not always provide a reasonable
safety margin; for example, an allowance is not always made
TECHNOLOGY
VACUUM
General Points
The following is a brief summary of some of the main
points which should be considered when designing or
specifying vacuum systems.
TECHNOLOGY
VACUUM
i) Use and correctly maintain in-line filters. Efficient
filtration will prevent solid debris or air borne particles
of oil and other contaminants fouling the vacuum pump
or internal orifices in vacuum ejectors. Ejectors should
be protected by filters both in the vacuum intake and in
the main supply lines.
Vacuum Symbols
The various standard ISO symbols, used to define vacuum
devices, are shown below. These can be used in a similar
fashion to the symbols for other pneumatic equipment and
follow similar conventions.
4.7
PNEUMATIC
ACTUATOR
TECHNOLOGY
TECHNOLOGY
PNEUMATIC
ACTUATOR
Pneumatic Actuators
5.1
maintenance. Depending on the application, these include:
1) Low break away force (stiction)
2) Minimum friction between the piston and barrel
3) Fast acceleration and deceleration
4) Accurate and repeatable positioning (especially in pick
and place systems)
TECHNOLOGY
PNEUMATIC
ACTUATOR
5) Maximum efficiency
6) Smooth operation
5.2
The Importance of the Piston Seal
Conventional linear actuators generally incorporate two lip
seals, mounted back to back and separated by a wear strip.
Although this arrangement provides an effective seal
between the piston rod assembly and the cylinder body it
TECHNOLOGY
PNEUMATIC
ACTUATOR
has a number of inherent drawbacks.
The large area of the lip seal, in contact with the cylinder
barrel, that is acted upon by the applied air pressure,
reduces the effective thrust of the piston and increases the
operating pressure necessary to start the piston moving; it
also inhibits smooth operation at slow speeds.
The movement of the lip seals along the barrel also tends to
scrape away the vital lubricating materials used to protect the
cylinder, so that they collect at either end of the bore. Over
time, this can result in the premature failure of the seals,
causing air losses and energy consumption to escalate.
5.3
In simple terms, the seal fits within a recess in the piston rod
and comprises a specially moulded, single piece, waisted
oval rubber element. This has a small contact area, to reduce
frictional losses to a minimum, and ensures a single point of
contact with the cylinder barrel, regardless of the air
pressure. As the cylinder reciprocates, the seal flexes about
TECHNOLOGY
PNEUMATIC
ACTUATOR
5.4
The Construction of Linear Actuators
Traditionally, linear actuators have been constructed from a
seamless tube or barrel, sealed at either end with end-caps
manufactured from alloy or iron castings and held in place
by longitudinal tie rods or screwed or crimped to the barrel.
Although this method of construction will probably continue
TECHNOLOGY
PNEUMATIC
ACTUATOR
for the foreseeable future, it is being supplemented by other
production techniques, most notably the use of high
pressure extrusion, pioneered by SMC, for the manufacture
of a one piece cylinder barrel, extruded from an aluminium
slug. This produces a simple, low cost cylinder, with a
minimum number of components.
5.5
extension; actuators that fall outside this tolerance band
provide poor positional accuracy and are likely to suffer
from increased wear of the piston seals.
PNEUMATIC
ACTUATOR
Rotary Actuators
There are two principal types of rotary actuator: rack and
pinion or vane. In the first, a linear piston movement is
translated into a rotary action by means of a rack and pinion
arrangement, giving a maximum rotation of 190°, while the
second type uses specially shaped vanes, driven by air
pressure, to turn an output shaft.
5.6
TECHNOLOGY
PNEUMATIC
ACTUATOR
Typical applications for these actuators are pick and place
systems, where a high level of positional accuracy is
required.
Rodless Cylinders
In a number of applications, especially where space is
limited or where extreme piston rod extension is required, a
conventional linear actuator is impractical because of the
combined length of the piston rod and cylinder body at full
extension. Rodless cylinders were developed to overcome
this problem and feature a carriage mounted directly above
the piston rod, enabling maximum use to be made of full
piston travel. A conventional cylinder with a stroke of
500mm, for example, will typically require a dimensional
length of 1100mm for installation, while a rodless cylinder
with a similar stroke requires only 600mm.
5.7
TECHNOLOGY
PNEUMATIC
ACTUATOR
Slide Units
In essence, slide units are precision linear actuators, but with
a twin piston rod arrangement to eliminate piston rotation
and increase the output force. Designed for use on automation
systems, especially where components need to be moved or
positioned, they can be used to replace traditional multi-
component actuator/guide rod assemblies.
5.8
TECHNOLOGY
PNEUMATIC
ACTUATOR
Pin or Needle Cylinders
Pin or needle cylinders are miniaturised devices, capable of
providing linear movement in confined spaces in
applications such as the electronics industry, where small
components need to be moved quickly from process to
process, or be clamped, rotated or ejected.
Combination Cylinders
Designed primarily for use in pick and place production
systems, combination cylinders provide multi-positional
movement in a single device; for example linear, rotary and
gripping actions.
5.9
SOLENOID
VALVES
Solenoid Valves
Solenoid valves are used widely throughout the pneumatics
SOLENOID
VALVES
industry, as an effective and reliable method of controlling
actuators and similar pneumatically operated devices.
6.1
SOLENOID
VALVES
The air gap between the armature and the coil also allows
the armature to be drawn radially against the inner wall of
the tube, again serving to increase friction and the build up
of heat and further affecting the operating life of the system.
In addition, the armature seals can rapidly degrade through
continuous impact with the metal seat around the inlet port.
6.2
SOLENOID
VALVES
At best, traditional solenoid pilot valves based on the Skinner
principle will have an operating life of between twenty and
thirty million cycles. Although this may be sufficient in some
applications, it can be a problem in modern automation or
pick and place systems, where high switching speeds and
often limited areas for installation place the various solenoid
components under severe stress. In addition, the high power
requirement of these devices - often in excess of 2W - often
makes them unsuitable for use in systems where direct
connection to PLCs or other digital controllers is required.
Recent Developments
SMC pneumatics was one of the first pneumatics
manufacturers to address the problems associated with
traditional solenoid pilot valves, in an effort to increase
reliability, operating life and response times, while decreasing
the level of power required.
6.3
as a single closed ring. This reduces the number of
components and, more importantly, removes the primary
cause for the disruption of the magnetic field.
6.4
To minimise wear still further the air gap between the
armature and core has been dramatically reduced, closing to
a minimum of 15 microns when the armature is energised.
This is sufficient to prevent the two components from
making contact, thereby eliminating the problems caused in
conventional solenoid valves by continuous collision
SOLENOID
damage, without impairing overall performance.
VALVES
Maintaining a minimum air gap also helps to break the
magnetic attraction between the core and armature as the
latter is de-energised, helping to reduce response times to
around 7msec for a valve with a double acting solenoid.
Power Requirements
Solenoid valves are available for use with either DC or AC
power sources. In simple terms, AC driven solenoid valves
are comparatively large devices, consuming higher levels of
power to produce a relatively slow action, while DC operated
valves use small, solid state components to produce fast
actions from compact devices; DC is commonly used with
most modern compact solenoid pilot valves.
6.5
A detailed explanation of electromagnetic theory and the
operating principles of DC and AC solenoids forms part of
SMC’s training course on electro-pneumatics (contact the
Training Department on 01908 563888 for more
information). There are, however, a number of general
points which should be considered.
SOLENOID
VALVES
6.6
Inrush Holding
Power DC
Power VA Power VA Power W
AC Frequency 50Hz 60Hz 50Hz 60Hz
Solenoid A 4.5 4.2 3.5 3.0 1.8
Solenoid B 5.6 5.0 3.4 2.3 1.8
SOLENOID
VALVES
In the case of DC (W=Watt), the current and voltage remain
constant. In the case of AC (VA=Volt Amperes), both voltage
and current change constantly. The difference in the figures
between 50Hz and 60Hz is due to the coil resistance.
Shading Ring
Each time the alternative current goes through zero, the
spring starts to return the armature. It will, in effect, only just
get free from the fixed force, and then is attracted again
when the current increases, with the opposite polarity.
6.7
Spring Characteristics
A crucial factor for the efficient operation of any solenoid
valve is the rapid and consistent return of the spring loaded
armature to the rest position as the coil is de-energised.
6.8
RODLESS CYLINDERS
Rodless cylinders were originally developed to overcome the
space limitations of conventional actuators, providing
relatively compact, space saving devices, capable of moving
CYLINDERS
or positioning components or tools in assembly and
RODLESS
automation systems.
7.1
Directly Coupled Rodless Cylinders
The latest generation of directly connected rodless cylinders,
such as SMC’s Series MY, make extensive use of aluminium
and special resins and plastics to ensure that the inertial
effects of the moving table assemblies are as low as possible
and to improve overall performance.
CYLINDERS
RODLESS
7.2
guided through a shaped groove in the top of the piston; this
effectively breaks and re-closes the seal as close to the table
assembly as possible, thereby reducing air losses to an
insignificant level. (See diagram below).
CYLINDERS
RODLESS
Dust and other contaminants are prevented from entering
the cylinder barrel by an NBR coated stainless steel dust
band that passes over the top of the piston at the point
where it locates in the base of the table. In addition, scraper
seals are used to keep the slide area free of debris, to ensure
that lubricants remain evenly distributed and to help guide
the belt seal and dust band.
7.3
magnets. As a result, the direct connection, slot and seal
arrangement in directly coupled rodless cylinders can be
dispensed with completely. (See diagram below).
CYLINDERS
RODLESS
Typical Applications
Rodless cylinders were originally developed for use in all
areas where space is restricted; they have, however, since
become used in a wide range of applications, as they
provide a simple, compact and reliable method of
transferring, moving or positioning components or
workpieces.
7.4
Basic Rules For Drawing Pneumatic Circuits
& Symbols
Pneumatic circuits are represented by common symbols and
should be drawn following several basic guidelines. By
CIRCUITS &
following these guidelines engineers can quickly and simply
SYMBOLS
construct circuits that can be easily and safely interpreted by
all those involved in system design, specification,
manufacturing and maintenance.
8.1
The situation can be further confused by the fact that the
Japanese Industry Standard (JIS) and the American Standards
Authority (ASA) also use differing sets of symbols.
8.2
INTELLIGENT ACTUATORS
What they are and how they work
Intelligent actuators have been developed for use in a wide
range of applications, in particular repetitive, multi-position
INTELLIGENT
ACTUATORS
tasks, such as single axis robotic automation, for drilling,
packaging and materials handling. They typically combine
long term, high accuracy stopping of a piston in mid-stroke,
even from high speeds, with programmable flexibility.
9.1
Relation between cylinder scale
displacement and output pulse
Direction of cylinder transfer is reversed
Cylinder
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
displacement
INTELLIGENT
ACTUATORS
mm
A phase
output pulse
B phase
output pulse
Counter value 0 1 2 3 4 3 2 1
9.2
while a continuous learning function compensates for
changing loads and other conditions.
INTELLIGENT
ACTUATORS
independent of load and speed.
9.3