FPE Module 5

SUBJECT: FLUID POWER ENGINEERING (18ME55)
MODULE 5: PNEUMATIC CONTROL CIRCUITS
PNEUMATIC CONTROL:
Pneumatic control involves the controlling of direction and velocity of pneumatic actuators
using control valves and pressurised air.
Control of actuators can broadly classified as Direct control and Indirect control.
In case of direct control, the actuator is directly controlled by a direction control valve
(DCV).
In case of indirect control, the controlling of the actuator by a DCV is through another control
valve called the pilot control valve. The pressure at which the pilot control valve operates is
called pilot pressure. Indirect controlling is done when more force is required to actuate the
DCV controlling the actuator. Such a DCV is called a pilot operated DCV.
DIRECT ACTUATION OF PNEUMATIC CYLINDERS:
Control of Single Acting Cylinder:
A single acting cylinder makes use of a 3/2 DCV.
Figure 1
When the push button is pressed, compressed air flows from port 1 to port 2 in the DCV
causing extension of the piston. On reaching the end of the extension stroke, the spring in the
cylinder retracts the piston. On releasing the push button, the DCV returns to its original
position by means of its retraction spring.
NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU
Control of Double Acting Cylinder:

A double acting cylinder makes use of a 5/2 DCV.
Figure 2
When the push button is pressed, compressed air flows from port 1 to port 4 in the DCV
causing extension of the piston. After reaching the end of the extension stroke, when the push
button is released, port 1 gets connected to port 2. This causes retraction of the piston making
the air to flow from port 4 to port 5.
INDIRECT ACTUATION OF PNEUMATIC CYLINDERS:

Control of Single Acting Cylinder:
The 3/2 DCV is actuated by a pilot valve which is also a 3/2 valve. When the push button of
the pilot valve is pressed, compressed air passes through its ports 1 and 2 thereby generating
a pilot signal 12. This actuates the main DCV so that the air flows through it and causes
extension of the cylinder. When the push button is released, air from the piston end of the
cylinder is vented to the atmosphere through the main valve. This causes retraction of the
cylinder.

VALACHIL, MANGALURU
Figure 3
Control of Double Acting Cylinder:

A double acting cylinder is controlled by using a double-piloted 5/2 DCV. Two 3/2 valves act
as pilot valves. One of them is for forward motion while the other one is for reverse position.
When the push button of the pilot valve on the left is pressed, a pilot signal 14 is generated.
This causes the main valve to move to its left envelope position so that the air pressure causes
extension of the piston. At the end of the extension stroke, the piston stops and does not
retract even if the button of left pilot valve is released. Hence, the 5/2 main valve is called a
memory valve. When the push button of the pilot valve on the right is pressed, the 5/2 way
valve switches back to initial position through the signal applied to its pilot port 12. The
piston then returns to its initial position and remains in the rear end position. Now even if the
return push button is released the status of the cylinder will not change. The circuit is called a
memory circuit because it uses a 5/2 way double pilot memory valve. 5/2 way valve can
remember the last signal applied in terms of the position of the spool in the absence of reset
springs, thus memorising or storing the pneumatic signal.

VALACHIL, MANGALURU
Figure 4
SPEED CONTROL OF PNEUMATIC CYLINDERS:

It is always necessary to reduce the speed of cylinder from maximum speed based on selected
size of final control valve to the nominal speed depending on the application. Speed control
of Pneumatic Cylinders can be conveniently achieved by regulating the flow rate of supply or
exhaust air. The volume flow rate of air can be controlled by using flow control valves which
can be either two way flow control valve or one way flow control valve.
There are two types of throttling circuits for double acting cylinders:
1. Supply air throttling
2. Exhaust air throttling
SUPPLY AIR THROTTLING:

This method of speed control of double acting cylinders is also called meter –in circuit
(Figure 5). For supply air throttling, one way flow control valves are installed so that air
entering the cylinder is throttled. The exhaust air can escape freely through the check valve of
the throttle valve on the outlet side of the cylinder. There is no air cushion on the exhaust side
of the cylinder piston with this throttling arrangement. As a result, considerable differences in

VALACHIL, MANGALURU
stroking velocity may be obtained even with very small variations of load on the piston rod.
Any load in the direction of operating motion will accelerate the piston above the set velocity.
Therefore supply air throttling can be used for single acting and small volume cylinders.
Figure 5
EXHAUST AIR THROTTLING:

This method of speed control of double acting cylinders is also called meter –out circuit
(Figure 6). In exhaust air throttling, the supply air flows freely to the cylinder and the exhaust
air is throttled. In this case, the piston is loaded between two cushions of air while the
cylinder is in motion and hence a smooth motion of the cylinder can be obtained. The first
cushion effect is due to supply air entering the cylinder through check valve, and second
cushion effect is due to the exhaust air leaving the cylinder through the throttle valve at a
slower rate. Therefore, exhaust air throttling is practically used for the speed control of
double acting cylinders. Arranging throttle valves in this way contributes substantially to the
improvement of feed behaviour.

VALACHIL, MANGALURU
Figure 6
SIGNAL PROCESSING ELEMENTS:

To meet the requirement of various conditions in pneumatic applications, signal processing
devices are often used. The ‘AND’ gate and ‘OR’ gate are used depending on the required
conditions.
These elements possess logic characteristics and are hence used in the design of logic
circuits.
USE OF ‘AND’ GATE:

Two 3/2 way valves S1 and S2 are connected in series. Both S1 and S2 are actuated so that
compressed air flows through both these valves. This generates a pilot signal 14 in the 5/2
DCV causing extension of the cylinder. The operation of both S1 and S2 simultaneously

VALACHIL, MANGALURU
means that the AND condition is met. When a either S1 or S2 is released, the signal at the 5/2
valve is reset and the piston rod retracts.
Figure 7
USE OF ‘OR’ GATE:

The inputs are connected to the working connections of the valves S1 and S2. Upon operation
of one of the push buttons, the corresponding valve S1 or S2 is actuated and a signal is
generated at one of the sides of the shuttle valve. The OR condition is fulfilled and the signal
passes through the shuttle valve and is emitted at port 2. The signal pressure is prevented
from escaping via the exhaust of the un-actuated valve by closing the line in the shuttle valve.
The signal effects the switching of the control element 1V2. The piston side of the cylinder is
pressurized and the piston rod advances.
When the actuated push button is released, the signal pressure is relieved via the valves S1
and S2 and the control element is switched back to its initial position. The pressure now
building up on the piston rod side ensures the retraction of the piston rod.

VALACHIL, MANGALURU
Figure 8

VALACHIL, MANGALURU
PRACTICAL EXAMPLES ON THE USAGE OF LOGIC GATES:

Example 1:
The piston rod of a cylinder is to advance only if a workpiece is inserted in the workpiece
retainer, a guard has been lowered and the operator presses the push button valve. Upon the
release of the push button or if the guard is no longer in lower position, the cylinder is to
retract to the initial condition.
Figure 9

VALACHIL, MANGALURU
Example 2:
The combined actuation of a manually actuated valve and a roller lever valve advances a
forming tool on an edge folding device. The forming tool is driven by a double acting
cylinder. For rapid forward travel, the circuit utilises a quick exhaust valve. The retracting
speed is to be adjustable. If either of the two valves is released, the tool returns to its initial
position.
Figure 10

VALACHIL, MANGALURU
Example 3:
A double acting cylinder is used to transfer parts from a magazine. If either a push button or
a front pedal is operated, the cylinder is to advance. Once the cylinder is fully advanced, it is
to retract to the initial position.
Figure 11

VALACHIL, MANGALURU
Example 4 :
A double acting cylinder is used to transfer parts from a magazine. The cylinder is to fully
advance when a push button is operated and then retract automatically. The speed of the
cylinder is adjustable in both the directions of motion.
Figure 12

VALACHIL, MANGALURU
QUICK EXHAUST VALVE CIRCUIT (For assignment):
Figure 13
USE OF LIMIT SWITCHES:
Limit switches are positioned at suitable locations in the path of travel of the piston rod of
the cylinder so that their actuation due to contact with the piston rod gives an indication of
the end position of the cylinder. The actuation of the limit switches sends signals for
reversing the path of travel of the piston rod. These limit switches may be of Roller Lever
type or of Idle Return Roller type.
(a) Roller Lever limit switch (b) Idle Return Roller limit switch
Figure 14

VALACHIL, MANGALURU
Roller Lever type Limit Switch gives mechanical signal which can be sensed in both
directions by the movement of piston rod cam.
Idle Return Roller Limit Switch gives mechanical signal due to actuation of roller only in one
direction.
AUTOMATIC CYLINDER RECIPROCATION CIRCUIT (For assignment):
Figure 15
TIME DELAY CIRCUIT:

A double-acting cylinder is used to press together glued components. Upon operation of a
push button, the clamping cylinder extends. Once the fully advanced position is reached, the
cylinder is to remain for a time of T= 6 seconds and then immediately retract to the initial
position. The cylinder retraction is to be adjustable. A new start cycle is only possible after
the cylinder has fully retracted.

VALACHIL, MANGALURU
Figure 16
PRESSURE DEPENDENT CONTROL:
A plastic component is embossed using a die driven by a double-acting cylinder. The die is to
advance and emboss the plastic when a push button is operated. The return of the die is to be
effected when a preset pressure is reached. The embossing pressure is to be adjustable.

VALACHIL, MANGALURU
Figure 17
MULTI-CYLINDER APPLICATION:
In most of the pneumatic applications, the job carried out is made up of a number of
independent and interrelated events. These events are carried out by independent pneumatic
elements especially actuators and such operations are called multi-cylinder operations. Each

VALACHIL, MANGALURU
cylinder has to be actuated (ie extended or retracted) in a particular sequence in a co-

ordinated manner. For example, while machining a component, the sequence of operations
followed is clamping- machining –de-clamping . Clamping and de-clamping can be done by
one cylinder while machining may be done by another actuator such as a pneumatic motor.
Any multi-cylinder application requires proper co-ordination and sequencing between the
events and hence between the actuators. The functional sequence and inter-relation between
cylinders can be easily represented and understood with the help of a functional diagram.
A functional diagram can be Motion diagram or Control diagram.
MOTION DIAGRAM:
A motion diagram is a graphical representation of conditions relating to working elements or
components. A motion diagram can be drawn for two variables of the working element such
as step or time. Hence there can be motion-step diagram or a motion-time diagram.
Motion-step diagram (Displacement-step diagram):
This diagram represents the operating sequence of a working element such as a cylinder or a
motor. The motion or displacement is recorded in relation to various steps that would occur
during a particular operation or process. The process of operation is divided into a number of
steps which are expressed in numbers 0,1,2, etc. positions are indicated as 1,2, etc..
For example, in extending and retracting of a cylinder, extension and retraction are steps
while remaining in extended or retracted states are considered as positions. The motion-step
diagram for a double acting cylinder is shown in fig. 17
Figure 18
Motion-time diagram (Displacement-time diagram):
This diagram represents the displacement of a component with respect to time. The time axis
‘t’ is drawn horizontally to scale and thus the relationship between individual components is
established.

VALACHIL, MANGALURU
Figure 19
CONTROL DIAGRAM:
A control diagram represents the condition of a control element in relation to the steps or the
times, the switching time itself not being considered. For example, the control diagram for a
3/2 spring return valve is shown in fig. 20.
Figure 20
It can be observed that the valve opens at step 1and remains open till step 4 when it closes. It
can be observed that the function lines are suddenly rising and dropping indicating that the
opening and closing of valves are instantaneous and not gradual.
The following procedure may be adopted for drawing a control diagram:
 The control diagram if possible should be drawn in conjunction with the motion
diagram.
 Steps or time should be entered horizontally.
 Height or separation are optional, but should be selected to ensure clarity.
The use of motion diagram is illustrated in the following examples:
Example 1:
Two cylinders are used to transfer parts from a magazine onto a chute (fig. 20). When a push
button is pressed, the first cylinder extends pushing the part from the magazine and positions
it in preparation for transfer by the second cylinder onto the out feed chute. Once the part is

VALACHIL, MANGALURU
transferred, the first cylinder retracts, followed by the second. Confirmation of all extended
and retracted positions are required.
Figure 21
Solution:
Let A be the first cylinder (positioning) and B be second cylinder (pushing). First cylinder A
extends and brings the part to the station where cylinder B is located. Cylinder B then extends
and pushes the part into the chute. Cylinder A can retract only cylinder B has retracted fully.
Representing the control tasks in notational form, we have:
Cylinder A advancing step is designated as A+

Cylinder A retracting step is designated as A-
Cylinder B advancing step is designated as B+
Cylinder B retracting step is designated as B-
Therefore, given sequence for clamping and stamping is A+B+A-B-
The Motion-step diagram and Motion-time diagram are plotted in fig. 21

VALACHIL, MANGALURU
Figure 22
Analysis of the circuit:

 When the start button is pressed, the signal appears at port 14 of 5/2 DCV of cylinder
A through limit switch signal b0.
 Check for the presence of the signal at the other end (12) of this valve. Notice that the
signal is not present at port 12 (because b1 is not pressed). There is no signal conflict
and the valve is able to move. So cylinder A advances to forward position.
 When cylinder A fully extends, it generates a limit switch signal a1, which is applied
to port 14 of 5/2 DCV of cylinder B so that cylinder B advances to forward position.
 Check for the presence of the signal at the other end (12) of this valve. Signal is not
present at port 12 of the valve (because a0 is not pressed, A is already in extended
position now) and hence there is no signal conflict.

VALACHIL, MANGALURU
 Signal applied to port 14 of this valve which causes its shifting and cylinder B
extends.
 When cylinder B fully extends, it generates a limit switch signal b1, which is applied
to port 12 of the DCV of cylinder A. Cylinder A returns and ao is pressed. There is no
signal conflict, as a0 and a1 are mutually exclusive signals.
 When the cylinder A is fully retracted, it generates a limit switch signal a0, which is
applied to port 12 of its DCV and Cylinder B retracts.
Figure 23
SIGNAL OVERLAP :
Signal Overlap can occur when simultaneously two active signals appear on both set and
reset pilot ports of Final Control Valve. This is due to the required sequencing of cylinder. At
the start, both signals a0 and b0 appear at the same time. This will not result in any change in
the position of the control valve.

VALACHIL, MANGALURU
Figure 24
In case of multi-cylinder operation, both set and reset signals could be present simultaneously
at any instant of time, depending on the sequential operation of the cylinder. This does not
permit further change in status of the valve. This situation is termed as signal over lap.
Consider the example below.
Example :
In a press shop, stamping operation to be performed using a stamping machine. Before

stamping, workpiece has to be clamped under stamping station. Then stamping tool comes
and performs stamping operation. Work piece must be unclamped only after stamping
operation.
Solution:
Let A be the first cylinder (clamping) and B be second cylinder (stamping). Cylinder A first
extends to clamp the workpiece. Cylinder B extends to position the tool for stamping
operation to commence. After completion of the stamping operation, cylinder B retracts.
After this cylinder A retracts.
Representing the control tasks in notational form, we have:
Cylinder A advancing step is designated as A+

Cylinder A retracting step is designated as A-
Cylinder B advancing step is designated as B+
Cylinder B retracting step is designated as B-
Therefore, given sequence for clamping and stamping is A+B+B-A-
The circuit diagram is constructed as below:

VALACHIL, MANGALURU
Figure 25
 When the push button is pressed, the signal 14 appears at the 5/2 DCV of cylinder A,
through the limit switch signal a0.
 The DCV shifts to the left envelope position and cylinder A advances to the forward
position. This is possible only if limit switch signal b0 is not generated (in other
words, b0 is not pressed)
 When the end of the piston rod of cylinder A contacts the limit switch a1, the signal
14 appears at the 5/2 DCV of cylinder B, causing the advance of cylinder B.
 When the piston rod of cylinder B contacts the limit switch b1, the signal 12 should
be generated the cylinder should normally retract. But since, the signal 14 exists
through the limit switch a1, there is conflict between signals 12 and 14 and retraction
of cylinder B does not happen.
 This can be observed through the motion-step diagram shown in figure 26 which
shows that there is signal overlap in the marked region.
 Hence the circuit cannot function in the sequence indicated and some signal
elimination method should be adopted.

VALACHIL, MANGALURU
Figure 26
SIGNAL ELIMINATION TECHNIQUES:

It is possible to eliminate signals either mechanically or by means of suitable circuitry.
1. Use of Idle return lever limit switches:

In this method signal elimination is done using idle return rollers. The use of idle return
rollers gives mechanical signal due to actuation of roller only in one direction. This
method however has some disadvantages:
 This method is not reliable
 End position cannot be sensed accurately
 Fast control system cannot be set up.
2. CASCADE METHOD (Use of Reversing Valves):

VALACHIL, MANGALURU
This method works on the principle that by tripping the air supply to the roller lever
valve causing signal overlap, the problem can be avoided.
Consider the two-cylinder co-ordinated motion A+B+B-A-
Let a1,b1, b0 and a0 be the limit switch signals for the above sequence, in that order.
Figure 27 (a)
Let the above sequence be split into two groups such that in a group a particular
cylinder motion occurs only once. Hence we have:
Figure 27(b)
Select one number of 5/2 DCV as the reversing valve (cascade valve).
The number of reversing valves is one less than the number of groups (2 in this case).
The last pilot trip valve getting actuated in a group will perform the function of changing air
supply from one group to another.
a0 which the last valve getting actuated in group 2 causes the reversing valve to change over
the air supply from group 2 to group 1.
Similarly b1 which the last valve getting actuated in group 1 causes the reversing valve to
change over the air supply from group 1 to group 2.
The pilot trip valves in a group will draw air from that group.

VALACHIL, MANGALURU
Group 1
Group 2
Reversing valve
Figure 28
The circuit shows both the cylinders A and B in retracted positions. Air supply exists in
group 2 through the reversing valve. When the 3/2 push button valve is actuated, a0 sends the
pilot signal 14 to actuate the reversing valve which changes to its left envelope configuration.
Now the air from group 2 line is exhausted to the atmosphere. Simultaneously, group 1 line
gets the air supply. This sends the pilot signal 14 to the 5/2 DCV of cylinder A causing its
extension. When the piston rod of cylinder A trips the roller lever valve a1, the air supply
from group 1 sends the pilot signal 14 to the 5/2 DCV of cylinder B causing its extension.
When the piston end of cylinder B trips the roller lever valve b1, it starts retracting.
Meanwhile, b1 sends the pilot signal 12 to actuate the reversing valve to change to its right

VALACHIL, MANGALURU
envelope configuration. Now the air from group 1 line is exhausted to the atmosphere.
Simultaneously, group 2 line gets the air supply. This causes air to flow through b0 applying
pilot pressure 12 on the 5/2 DCV of cylinder A causing it to retract consequent to the
retraction of cylinder B.
ELECTRO-PNEUMATIC CONTROL:
A pneumatic control system with solenoid operated valves may be called an electro-
pneumatic system. An electro-pneumatic system consists of a pneumatic driving element and
an electromechanical control part. The electro-mechanical parts used consist mostly of a
solenoid controlled by push button switches, relays, contactors, limit switches, etc.
Switches can be wired either normally open (NO) or normally closed (NC). A normally open
switch is one in which no electric current can flow through the switching element until the
switch is actuated. In a normally closed switch, electric current can flow through the
switching element until the switch is actuated.
SIGNAL INPUT AND OUTPUT:
In Electro pneumatic controls, mainly three important steps are involved:
 Signal input through devices such as switches and contactor,
 Signal Processing by the use of combination of Contactors of Relay or using
Programmable Logic Controllers
 Signal Out puts obtained after processing are used for activation of solenoids, which
actuate the final control elements like DCV.
SOLENOIDS:
Solenoids are electromagnets that provide a push or pull force to operate pneumatic valves
remotely. A solenoid has basically two parts- a coil and an armature. When the coil is
energised, it creates a magnetic force that pulls the armature into the coil. The armature in
turn pushes a push pin to move the spool of the valve.

VALACHIL, MANGALURU
Figure 29
CONTACTORS (Switches):
These are control members used to make or break the electrical circuit for the solenoid
operated valves.
There are five basic types of electric switches used in electro-pneumatic circuits: push button,
limit, pressure, temperature and relay switches.
Push-button switches:
Usually push button type of switches are used in pneumatic circuits wherever an electric
signal is to be fed to start and stop an operation manually. They make or break contacts only
as long as they are held pressed and are hence termed as momentary switches.
Four types of common push-button switches are shown in fig.
Figure 30
i) Single-pole, single-throw type – normally open (SPST- NO):
These are wired normally open.
ii) Single-pole, single-throw type – normally closed (SPST-NC):
These are wired normally closed.

VALACHIL, MANGALURU
iii) Double-pole, single-throw type (DPST):

This has one normally open and one normally closed pair of contacts. Depressing
the push button opens the normally closed pair and closes the normally open pair
of contacts.
iv) Double-pole, double-throw type (DPDT):
This has two pairs of normally open and two pairs of normally closed contacts to
allow the inverting of two circuits with one input.
Limit Switches:
Limit Switches are used to identify the extreme limits of the cylinder actuation. Limit
switches open and close circuits when they are actuated either at the end of the retraction or
extension strokes of the cylinder.
Basically, the limit switches perform the same functions as push-button switches. The
difference is that they are mechanically actuated and not manually actuated. Limit switch can
be normally open (LS-NO) or normally closed (LS-NC) as shown in fig.
Figure 31
A number of operators are available for limit switches. Among these are cams, levers, rollers
and plungers.
.
Relays:
Relays are switches whose contacts open or close when their corresponding coils are
energised. They are commonly used for energising and de-energising of solenoids because
they operate at high current level. In this way a manually actuated switch can be operated at
low voltage levels to protect the operator. This low-voltage circuit can be used to energise
relay coils that control high-voltage contacts used to open and close circuits containing the
solenoids.

VALACHIL, MANGALURU
Fig.32 shows the working of a relay.

When the switch 1-SW is closed, the coil (electromagnet) is energised. This pulls on the
spring-loaded relay arm to open the upper set of normally closed contacts and close the lower
set of normally open contacts.
Figure 32
CONTROL CIRCUITRY FOR CYLINDERS:

Pneumatic cylinders can be controlled electrically in various ways. In fig.31(a) , a double
acting cylinder is to be operated by a 4/2 solenoid controlled DCV. b1 and b2 are the limit
switches to actuate the DCV. Four methods of electrical switching possibilities are shown in
fig.31
The simplest method is as shown in fig.31 (b) when a manually operated contact switch S is
used to energise the solenoid coil C which makes the cylinder to advance. The return of the
cylinder to its initial position is done by releasing the contact switch S.
In fig.31 (c) a relay R is used to carry the signal of the solenoid.
In case it is desired that the cylinder remain actuated even if the switch S1 is released, then the
switching diagram in fig.31 (d) could be used. The cylinder will alternate only after
momentary pushing of push buttons S1 or S2 .
VALACHIL, MANGALURU
If the cylinder is to return to its initial position on completing its stroke length, the OFF push
button S2 in fig 31 (d) can be replaced with a NC limit switch b2 located at the end of the
cylinder as illustrated in fig. 31 (e)
Figure 33

VALACHIL, MANGALURU
Control of double acting cylinder using a 4/2 solenoid actuated spring return valve:
Figure 34
When the push button switch is actuated, the contact K1 closes through its relay thereby
energising the solenoid valve Y1. This in turn actuates the 4/2 DCV to its left envelope
position causing extension of the cylinder. When the push button is released, the contact K1
opens and the solenoid valve denergises. The 4/2 DCV returns to its right envelope position
because of spring retraction, causing the cylinder to retract.
Control of double acting cylinder for forward and reverse motion:
When the push button connected to relay Y1 is pressed, the contact K1 closes. This actuates
the solenoid valve Y1 which creates pilot signal 14, thereby causing extension of the
cylinder. When the push button connected to relay Y2 is pressed, the contact K2 closes. This
actuates the solenoid valve Y2 which creates pilot signal 12, thereby causing retraction of the
cylinder.

VALACHIL, MANGALURU
Figure 35
______

VALACHIL, MANGALURU
QUESTION BANK
1. Explain the following operations in pneumatic systems:

(a) Direct actuation of single acting cylinder
(b) Direct actuation of double acting cylinder
(c) Indirect actuation of single acting cylinder
(d) Indirect actuation of double acting cylinder
2. Why is a 5/2 pilot-operated directional control valve called a memory valve?
3. Explain the process of supply air throttling with a neat circuit diagram.
4. Explain the process of exhaust air throttling with a neat circuit diagram.
5. With neat circuit diagrams explain the working of pneumatic circuits using “OR” and
“AND” gate valves.
6. The piston rod of a cylinder is to advance only if a workpiece is inserted in the workpiece
retainer, a guard has been lowered and the operator presses the push button valve. Upon
the release of the push button or if the guard is no longer in lower position, the cylinder is
to retract to the initial condition. Construct a suitable circuit and explain the working.
7. The combined actuation of a manually actuated valve and a roller lever valve advances a
forming tool on an edge folding device. The forming tool is driven by a double acting
cylinder. For rapid forward travel, the circuit utilises a quick exhaust valve. The retracting
speed is to be adjustable. If either of the two valves is released, the tool returns to its
initial position. Construct a suitable circuit and explain the working.
8. A double acting cylinder is used to transfer parts from a magazine. If either a push button
or a front pedal is operated, the cylinder is to advance. Once the cylinder is fully
advanced, it is to retract to the initial position.
9. Construct a circuit diagram for the automatic reciprocation circuit of a double acting
cylinder.
10. What is a motion diagram? What are its types?
11. What is a control diagram?
12. Two cylinders are used to transfer parts from a magazine onto a chute. When a push
button is pressed, the first cylinder extends pushing the part from the magazine and
positions it in preparation for transfer by the second cylinder onto the out feed chute.
Once the part is transferred, the first cylinder retracts, followed by the second.

VALACHIL, MANGALURU
Confirmation of all extended and retracted positions are required. Construct a circuit
diagram and explain the working.
13. What is signal overlap in a pneumatic direction control valve? How can it be eliminated?
14. In a press shop, stamping operation to be performed using a stamping machine. Before
stamping, workpiece has to be clamped under stamping station. Then stamping tool
comes and performs stamping operation. Work piece must be unclamped only after
stamping operation.
(a) Construct a circuit diagram and analyse how the conflict of signal occurs.
(b) Reconstruct the circuit using the cascading method (by using reversing valve) and
analyse its working.
15. List and write briefly about the push button switches used in electro-pneumatic circuits.
16. What is a relay? Explain its working in an electro-pneumatic circuit.
17. Construct a circuit diagram for controlling the actuation of a double acting cylinder
using a 4/2 solenoid actuated spring return valve:
18. Construct a circuit diagram for controlling the actuation of a double acting cylinder
using a 4/2 solenoid for both forward and reverse motions.
----------------

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SUBJECT: FLUID POWER ENGINEERING (18ME55)

MODULE 5: PNEUMATIC CONTROL CIRCUITS

Control of Single Acting Cylinder:

A single acting cylinder makes use of a 3/2 DCV.

NOTES BY SANDESH M PRABHU,

Control of Double Acting Cylinder:

INDIRECT ACTUATION OF PNEUMATIC CYLINDERS:

NOTES BY SANDESH M PRABHU,

Control of Double Acting Cylinder:

NOTES BY SANDESH M PRABHU,

SPEED CONTROL OF PNEUMATIC CYLINDERS:

SUPPLY AIR THROTTLING:

NOTES BY SANDESH M PRABHU,

EXHAUST AIR THROTTLING:

NOTES BY SANDESH M PRABHU,

SIGNAL PROCESSING ELEMENTS:

USE OF ‘AND’ GATE:

NOTES BY SANDESH M PRABHU,

USE OF ‘OR’ GATE:

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

PRACTICAL EXAMPLES ON THE USAGE OF LOGIC GATES:

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

QUICK EXHAUST VALVE CIRCUIT (For assignment):

USE OF LIMIT SWITCHES:

NOTES BY SANDESH M PRABHU,

AUTOMATIC CYLINDER RECIPROCATION CIRCUIT (For assignment):

TIME DELAY CIRCUIT:

NOTES BY SANDESH M PRABHU,

PRESSURE DEPENDENT CONTROL:

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

cylinder has to be actuated (ie extended or retracted) in a particular sequence in a co-

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

Cylinder A advancing step is designated as A+

The Motion-step diagram and Motion-time diagram are plotted in fig. 21

NOTES BY SANDESH M PRABHU,

Analysis of the circuit:

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

In a press shop, stamping operation to be performed using a stamping machine. Before

Cylinder A advancing step is designated as A+

The circuit diagram is constructed as below:

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

SIGNAL ELIMINATION TECHNIQUES:

1. Use of Idle return lever limit switches:

2. CASCADE METHOD (Use of Reversing Valves):

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

NOTES BY SANDESH M PRABHU,

iii) Double-pole, single-throw type (DPST):

NOTES BY SANDESH M PRABHU,

Fig.32 shows the working of a relay.

CONTROL CIRCUITRY FOR CYLINDERS:

NOTES BY SANDESH M PRABHU,

Control of double acting cylinder for forward and reverse motion: