Advanced Electro Pneumatics and It's Applications: Courseware Manual

Introduction to Advanced Electro Pneumatics
Advanced
Electro
Pneumatics
and It’s
Applications
Courseware Manual
Page 1
Contents
1 PNEUMATICS – An overview ......................................................................................................... 3
1.1 FUNCTIONS OF PNEUMATICS: ............................................................................................... 3
1.1.1 TYPES OF MOTION PERFORMED BY PNEUMATIC COMPONENTS: ................................. 3
1.1.2 APPLICATIONS OF PNEUMATIC SYSTEM:........................................................................ 3
2 ADVANCE ELECTRO PNEUMATIC SYSTEM .................................................................................... 6
2.1 PNEUMATIC ........................................................................................................................... 6
2.2 CONTROL ............................................................................................................................... 6
2.3 ELECTRICAL INTRODUCTION ................................................................................................. 6
2.4 CLASSIFICATION OF CONTROLLERS ....................................................................................... 7
2.5 STRUCTURE AND MODE OF OPERATION OF A ELECTRO PNEUMATIC CIRCUIT .................... 8
2.6 INTRODUCTION OF ELECTRO PNEUMATICS ........................................................................ 10
2.7 DC SUPPLY............................................................................................................................ 10
3 FUNDAMENTAL OF ELECTRICAL TECHNOLOGY .......................................................................... 12
4 STUDY OF BASIC COMPONENTS ................................................................................................. 16
5 ADVANCE ELECTRO PNEUMATIC CIRCUITS ................................................................................ 17
5.1 STUDY OF LATCHING............................................................................................................ 17
5.2 STUDY OF CASCADING CIRCUIT ........................................................................................... 21
5.3 STUDY OF CASCADING CIRCUIT ........................................................................................... 25
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1 Pneumatics – An Over View

Fluid power system using air as a medium for developing, transmitting, controlling and utilizing
power is commonly referred to as Pneumatics. Pneuma is a Greek word means Breath or Wind or Air.
Pneumatics means the study of air movement and air phenomena. Today it is not possible to
imagine the modern industry without using Pneumatics for the automation. It finds application in the
diverse branch of the industry. The real practical industrial application of Pneumatics in production
dates back to about 1950.
1.1 Functions of Pneumatics:

In Pneumatics in the majority of applications compressed air is used for one or more of the
following functions.
 The use of sensor to determine status of process.
 Information processing.
 Switching of actuators by means of final control elements.
 Carrying out of work.
1.1.1 The Types of Motion Performed By Pneumatic Components:

 Linear
 Swivel
 Rotary.
1.1.2 Applications of Pneumatic System:

General methods of Material handling
 Clamping
 Shifting
 Positioning
 Orienting

General applications
 Opening of system valves for Air, Water or Chemicals
 Packaging
 Door or Chute control
 Forming operations like bending, drawing etc.,
 Stamping and embossing of components
 Feeding and Transfer of materials.
 Turning and inverting of parts.
 Stacking of components.
 Sorting of parts.
 Spot welding
 Pick and place operations
 Work or tool feeding in Machine tools
 Dental drills etc.,

Question & Answer:
1) Pressure of 1 bar is equal to

14.5 psi
2) Name three speed control circuits?
1. Meter - out circuit
2. Meter - in circuit
3. Bleed - off circuit
3) What are the main components in pneumatic?

Pneumatic components can be divided into two categories:
Components that produce and transport compressed air.
Components that consume compressed air.
4) How can you control cylinder speed?

Use a position feedback cylinder with a closed loop controller.
5) How do you get more power out of a particular cylinder?

Should increase the pressure of the air that feeds the cylinder within the recommended
limits.

2. Advanced Electro Pneumatic System:
2.1 Pneumatics:
Pneumatics deals the use of compressed air. Most commonly, compressed air is used to do
mechanical work – that is to produce motion and to generate forces. Pneumatic drives have the task
of converting the energy stored in compressed air into motion. Cylinders are most commonly used for
pneumatic drives. They are characterized by robust construction, a large range of types, simple
installation and favorable price/performance. As a result of these benefits, pneumatics is used in a
wide range of applications.
2.2 Control
Controlling – open loop control – is that process taking place in a system whereby one or more
variables in the form of input variables exert influence on other variables in the form of output
variables by reason of the laws which characterize the system. The distinguishing feature of open loop
controlling is the open sequence of action via the individual transfer elements or the control chain
Controls must evaluate and process information (for example, pushbutton pressed or not
pressed). The information is represented by signals. A signal is a physical variable, for example
 The pressure at a particular point in a pneumatic system.
 The voltage at a particular point in an electrical circuit.
2.3 Electrical - Introduction

A signal is the representation of information the representation is by means of the value or
value pattern of the physical variable
Analog signal
An analog signal is a signal in which information is assigned point by point to a continuous
value range of the signal parameter
Digital signal
A digital signal is a signal with a finite number of value ranges of the information parameter.
Each value range is assigned a specific item of information
Binary signal
A binary signal is a digital signal with only two value ranges for the information parameter.
These are normally designated o and 1


2.4 Classification of controllers.
Controllers can be divided into different categories according to the type of information
representation, into analogue, digital and binary controllers
Logic controller
A logic controller generates output signals through logical association of input signals.
Sequence controller
A sequence controller is characterized by its step by step operation. The next step can only be
carried out when certain criteria are met.
Signal flow in a control system

 A controller can be divided into the functions signal input, signal processing, signal output
and command execution. The mutual influence of these functions is shown by the signal
flow diagram.
 Signals from the signal input are logically associated (signal processing). Signals for signal
input and signal process are low power signals. Both functions are part of the signal control
section.
 At the signal output stage, signals are amplified from low power to high power. Signal
output forms the link between the signal control section and the power section.
 Command execution takes place at a high power level – that is, in order to reach a high
speed (such as for fast ejection of a workpiece from a machine) or to exert a high force
(such as for a press). Command execution belongs to the power section of a control system.

Electro pneumatic controllers have a pneumatic power section. The signal control section
varies according to type.
 In a pneumatic control, pneumatic components are used, that is, various types of valves,
sequencers, air barriers, etc.
 In an electro-pneumatic control, the signal control section is made up of a electrical
components, for example with electrical input buttons, proximity switches, relays, or a
programmable logic controller.
 The directional control valves form the interface between the signal control section and the
pneumatic power section in both types of controller.
2.5 Structure and mode of operation of an electro pneumatic controller

 The electrical signal control section switches the electrically actuated directional control
valves.
 The directional control valves cause the piston rods to extend and retract.
 The position of the piston rods is reported to the electrical signal control section by
proximity switches

Power Components
 Cylinder
 Swivel Cylinder
Command Execution Pneumatic motors
Optical displays
Final control elements

Electro pneumatically
Signal Output Operated directional control
valves
Processing elements
Relays
Contactors
Signal Processing Programmable logic controllers
(PLC)
Input elements
Push buttons
Control switches
Limit switches
Reed switches
Signal Output Ind.proximity switches
Cap.proximity switches
Pressure actuated
Switches
Signal Flow
Electro pneumatic components

2.6 Introduction to electro-pneumatics
Electro-pneumatic is widely used in many areas of industrial automation. Production, assembly,
and packaging systems worldwide. These systems are driven by electro-pneumatic control systems.
In electro-pneumatics, the pneumatic components are controlled by using electrical and electronic
circuits. Electronic and electromagnetic sensors, electrical switches and industrial computers are used
to replace the manual control of a pneumatic system.
2.7 DC Power Supply

The power supply is used to reduce and convert the 230 V AC to a 24 V DC
The transformer reduces the main voltage (230 to 24 volt).

 The rectifier converts the AC voltage to DC voltage.
 The stabilizer is used to smooth and maintain constant voltage at the output.
The following criteria play commonly an important role is selecting the power supply:
 The magnitude of voltage and current it can supply.
 How stable its output voltage or current is under varying load conditions.
 Whether it provides continuous or pulsed energy.
Advantages of electro pneumatic controller:

 Higher reliability (fewer moving parts subject to wear).
 Lower planning and commissioning effort, particularly for complex controls.
 Lower installation effort, particularly when modern components such as valve terminals
are used.
 Simpler exchange of information between several controllers.

Question & Answer:
1) Types of controller?
 Analog controller
 Digital controller
 Binary controller
2) What are the types of energy supply elements?

 Compressor
 Reservoir
 Pressure regulating valve
3) What are the types of power components?

 Cylinder
 Pneumatic motor
 Optical display
4) In pneumatic systems, AND gate is also known as

Dual Pressure Valve
5) What is a pressure sequence valve?

It is a combination of adjustable pressure relief valve and directional control valve

3. Fundamentals of Electrical Technology

Physically, charge carriers – electrons – move through the electrical circuit via the electrical
conductors from the negative pole of the voltage source to the positive pole. This motion of charge
carriers is called electrical current. Current can only flow if the circuit is closed.
There are two types of current - direct current and alternating current:
 If the electromotive force in an electrical circuit is always in the same direction, the current
also always flows in the same direction. This is called direct current (DC) or a DC circuit.
 In the case of alternating current or an AC circuit, the voltage and current change direction and
strength in a certain cycle.
Electrical conductor
Electrical current is the flow of charge carriers in one direction. A current can only flow in a
material if a sufficient number of free electrons are available. Materials that meet this criterion are
called electrical conductors.
Electrical resistance
Every material offers resistance to electrical current. This result when the free moving
electrons collide with the atoms of the conductor material, inhibiting their motion. Resistance is low in
electrical conductor. Materials with particularly high resistance are called insulators.

Source emf
The negative pole of a voltage source has a surplus of electrons. The positive pole has a deficit.
This difference results in source emf (electromotive force).
Ohm's law
Ohm's Law deals with the relationship between voltage and current in an ideal conductor.
The potential difference (voltage) across an ideal conductor is proportional to the current through it.
The constant of proportionality is called the "resistance", R.
Ohm's Law is given by:
V=IR
Where V is the potential difference between two points which include a resistance R. ‘I’ is the
current flowing through the resistance. For biological work, it is often preferable to use the
conductance.
Electric power
Electric power is the rate at which electric energy is transferred by an electric circuit.
The electrical power of a load is also called its electrical power input.
P = V. I
Where,
P = Power; Unit: Watt (W)
V = Voltage; Unit: Volt (V)
I = Current; Unit: Ampere (A)
Solenoid
A solenoid is defined as a coil of wire commonly in the form of a long cylinder that when
carrying a current resembles a bar magnet so that a moveable core is drawn into the coil when a
current flows. A more simple definition is that a solenoid is a coil and a moveable iron core used to
convert electrical energy into mechanical energy.
Function of a solenoid
The core material is ferromagnetic, meaning that it concentrates magnetic lines of flux. This
increases the inductance of the coil far beyond the inductance obtainable with an air-core coil of the
same dimensions and the same number of turns. When current flows in the coil, most of the resulting
magnetic flux exists within the core material. Some flux appears outside the coil near the ends of the
core; a small amount of flux also appears outside the coil and off to the side.

Sequential circuit
By sequencing a number of pneumatic cylinders, various machining and tooling operations
may easily be obtained in a machine. By using this technique, the cylinders can be actuated one after
another in sequences like clamping, feeding and ejecting (or) lifting, pushing and clamping (or) in
various other combinations. The electro-pneumatic circuit utilizing this technique is known as
automatic sequencing circuit. Correct sequence of motion of each cylinder and the respective cycle
time, should be carefully studied before designing such a circuit.
So, Process control electro-pneumatics is also called as sequencing. It means performing
number of actions one after another which follows each other in a simple order or with an order
determined by sensors.

Question & Answer:
1) Define EMF?
Electromotive force, also called emf (denoted and measured in volts), is the voltage
developed by any source of electrical energy such as a battery or dynamo. It is generally
defined as the electrical potential for a source in a circuit.
2) Unit of power?
Watt
3) Define ohms law?

Applied voltage equals circuit current times the circuit resistance.
V=IR
4) What is resistor?
Resistance is the force that reduces or stops the flow of electrons. It opposes voltage.
5) What is Time Period?

It is the Time Taken in seconds to complete one cycle of an alternating quantity.

4 Study of components:
*Basic components are already discussed in Basic pneumatic & its application course and Basic Electro
pneumatics & its application.

5 Study of Advance Electro pneumatic circuits:
5.1 Study of latching:
Objective:
Design of Electro pneumatic circuit with auto-retraction by using latching circuit and sensor.
List of components required:

Circuit:
Variable assignment:
Variable assignment is used to inter linking of electrical component with sensors and
electrically operated valves and actuators.
In above circuit, proximity sensor (prox1) is inter linked with NC proximity sensor switch.
Coil1 is inter linked with the NO contact and solenoid (sol) output is inter linked with solenoid
operated 5/2 NO Direction Control Valve.

STEP1: Drag and drop the proximity sensor in work area, modify Variable pop-up window will
appear and enter a proximity name in tag name text box.
STEP2: Double click on proximity NC switch (or) right click on proximity NC switch and select
Component properties.
STEP4: Select “variable assignment” and select appropriate “Component Variable” with
“Internal Links”.
STEP5: Click on “Link” button, then click “Apply” and select “Close” button.
STEP6: Drag and drop the solenoid in work area, modify Variable pop-up window will appear
and enter a solenoid name in tag name text box.
STEP7: Double click on 5/2 NO Direction Control Valve (or) right click on 5/2 NO Direction
Control Valve and select Component properties.
STEP10: Drag and drop the coil in work area, modify Variable pop-up window will appear and
enter a coil name in tag name text box.
STEP11: Double click on NO contact (or) right click on NO contact and select Component
properties.
Working procedure
 Push button is operated, then coil (coil1) is energized and it makes solenoid(sol) to
energized.
 Coil (coil1) is connected parallel to push button. So, there is continuous power supply even

after push button released.
 Solenoid (sol) is interlinked with solenoid operated 5/2 NO direction control valve. 5/2 NO
direction control valve is moved to position1 and extension stroke is performed.
 At the end of extension stroke, proximity sensor is sensed.
 Coil will de-energized and makes solenoid operated 5/2 NO direction control valve is
operated to position1. Retraction stroke is performed.
Simulation:

5.2 Study of cascading circuit (A+B+B-A-):
Cascading:
Implementation of a sequence of actions in a pneumatic circuit.
Symbol Description
+ Extension stroke
- Retraction stroke
Objective:
Design a pneumatic circuit using electrical control to perform A+B+B-A- sequence.

Circuit:

In above circuit, proximity sensor (sol1) is inter linked with NC proximity sensor switch.
Coil1 is inter linked with the NO contact and solenoid (sol1) output is inter linked with solenoid
operated 5/2 NO Direction Control Valve. Likewise other sensors and solenoid are inter linked.
STEP1: Drag and drop the proximity sensor in work area, modify Variable pop-up window will
appear and enter a proximity name in tag name text box.
STEP2: Double click on proximity NC switch (or) right click on proximity NC switch and select
Component properties.
STEP6: Drag and drop the solenoid in work area modify Variable pop-up window will appear
and enter a solenoid name in tag name text box.
STEP7: Double click on 5/2 NO Direction Control Valve (or) right click on 5/2 NO Direction
Control Valve and select Component properties.
STEP10: Drag and drop the coil in work area, modify Variable pop-up window will appear and
enter a coil name in tag name text box.
STEP11: Double click on NO contact (or) right click on NO contact and select Component
properties.
* Similar to proximity sensor (Sol1, Sol2, Sol3 & Sol4) , Solenoid ( Sol1, Sol2, Sol3 & Sol4) and
Coil ( K1, K2, K3 & K4) is interlinked.
Working procedure:
 Lever operated 3/2 NO direction control valve is operated to position1, and electrically
operated push button is pressed.
 Coil (K1) and solenoid (sol1) is energized, makes solenoid operated NO 5/2 direction control
valve for double acting cylinder (A) to operate to position1 and extension stroke is
performed (A+).

 At the end of A+, proximity sensor (sol2) is sensed and Solenoid (Sol3) is energized, makes
solenoid operated NO 5/2 direction control valve for double acting cylinder (B) to operate
to position1 and extension stroke is performed (B+).
 At the end of B+, proximity sensor (sol4) is sensed and Solenoid (Sol4) is energized, makes
solenoid operated NO 5/2 direction control valve for double acting cylinder (B) to operate
to position2 and extension stroke is performed (B-).
 At the end of A+, proximity sensor (sol3) is sensed and Solenoid (Sol2) is energized, makes
solenoid operated NO 5/2 direction control valve for double acting cylinder (A) to operate
to position2 and extension stroke is performed (A-).
Simulation:

5.3 Study of cascading circuit (A+B+C+A-B-C-):
Objective:
Design a pneumatic circuit using electrical control to perform A+B+C+A-B-C- sequence.

Circuit:
In above circuit, proximity sensor (A1, A2, B1, B2, C1 & C2) is inter linked with NC proximity sensor
switch.
Solenoid (S1, S2, S3, S4, S5 & S6) output is inter linked with solenoid operated 5/2 NO Direction
Control Valve (for double acting cylinder1, 2 & 3).

Working procedure:
 Lever operated 3/2 NO direction control valve is operated to position1 to start sequence.
 Electrical operated push button is operated to energize coil (K1) AND solenoid (S1) and
solenoid operated 5/2 NO direction control valve for double acting cylinder1 is operated to
position1.
 Extension stroke is performed (A+) and at the end of extension stroke, proximity sensor (A2)
is sensed and solenoid (S2) is energized.
 Solenoid operated 5/2 NO direction control valve for double acting cylinder2 is operated to
position1 and Extension stroke is performed (B+).
 At the end of extension stroke, proximity sensor (B2) is sensed and solenoid (S3) is
energized. Solenoid operated 5/2 NO direction control valve for double acting cylinder3 is
operated to position1 and Extension stroke is performed (C+).
 At the end of extension stroke, proximity sensor (C2) is sensed and solenoid (S4) is
operated to position2 and Retraction stroke is performed (A- ).
 At the end of retraction stroke, proximity sensor (A1) is sensed and solenoid (S5) is
operated to position2 and Retraction stroke is performed (B- ).
 At the end of extension stroke, proximity sensor (B2) is sensed and solenoid (S6) is
operated to position2 and Retraction stroke is performed (C- ).

Simulation:

Question & Answer:
1) What are the types of linear cylinder?

 Single acting cylinder
 Double acting cylinder
2) In single actuating cylinder, which type of valve is used?

3/2 valve. Because it has one port.
3) What is meant by fluid conditioning?

The combination of filter, regulator and lubricator.
4) What is meant by indicators?

Optical indicators visually represent the operating status of the pneumatic system.
Some of the visual devices are,
 Counters – for displaying counting cycles
 Pressure gauge – To indicate the pressure values
 Timers – visual indication of time delay
5) Operating position of 5/3 valve?

5/3 valve to control a double-acting cylinder. The valve has two solenoids (s1 & s2)
S1=ON & S2=OFF, this will be Position1
S1=OFF & S2=OFF, this will be Position2 (center)
S1=OFF & S2=ON, this will be Position3

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Introduction to Advanced Electro Pneumatics

1.1 FUNCTIONS OF PNEUMATICS: ............................................................................................... 3

1.1.1 TYPES OF MOTION PERFORMED BY PNEUMATIC COMPONENTS: ................................. 3

1.1.2 APPLICATIONS OF PNEUMATIC SYSTEM:........................................................................ 3

2 ADVANCE ELECTRO PNEUMATIC SYSTEM .................................................................................... 6

2.1 PNEUMATIC ........................................................................................................................... 6

2.2 CONTROL ............................................................................................................................... 6

2.3 ELECTRICAL INTRODUCTION ................................................................................................. 6

2.4 CLASSIFICATION OF CONTROLLERS ....................................................................................... 7

2.5 STRUCTURE AND MODE OF OPERATION OF A ELECTRO PNEUMATIC CIRCUIT .................... 8

2.6 INTRODUCTION OF ELECTRO PNEUMATICS ........................................................................ 10

3 FUNDAMENTAL OF ELECTRICAL TECHNOLOGY .......................................................................... 12

4 STUDY OF BASIC COMPONENTS ................................................................................................. 16

5 ADVANCE ELECTRO PNEUMATIC CIRCUITS ................................................................................ 17

5.1 STUDY OF LATCHING............................................................................................................ 17

5.2 STUDY OF CASCADING CIRCUIT ........................................................................................... 21

5.3 STUDY OF CASCADING CIRCUIT ........................................................................................... 25

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1 Pneumatics – An Over View

1.1 Functions of Pneumatics:

1.1.1 The Types of Motion Performed By Pneumatic Components:

1.1.2 Applications of Pneumatic System:

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1) Pressure of 1 bar is equal to

2) Name three speed control circuits?

1. Meter - out circuit

3. Bleed - off circuit

3) What are the main components in pneumatic?

4) How can you control cylinder speed?

5) How do you get more power out of a particular cylinder?

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2. Advanced Electro Pneumatic System:

2.3 Electrical - Introduction

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Signal flow in a control system

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2.5 Structure and mode of operation of an electro pneumatic controller

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Final control elements

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2.7 DC Power Supply

The transformer reduces the main voltage (230 to 24 volt).

Advantages of electro pneumatic controller:

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2) What are the types of energy supply elements?

3) What are the types of power components?

4) In pneumatic systems, AND gate is also known as

5) What is a pressure sequence valve?

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3. Fundamentals of Electrical Technology

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3) Define ohms law?

5) What is Time Period?

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5 Study of Advance Electro pneumatic circuits:

5.1 Study of latching:

List of components required:

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