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Electro-Pneumatics

Introduction to Electro-pneumatics
Electro-Pneumatics
Definition :

§ Electro-pneumatic term is defined from the words of electro which

means electrical and pneumatic which means pressurized air.

§ Electro pneumatic is a pneumatic control system where air pressure and

direction of valve are controlled by an electrical current.

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Introduction to Electro-pneumatics
Electro pneumatics is now commonly used in many areas of Industrial low cost
automation.
They are also used extensively in;
• production,
• assembly,
• pharmaceutical,
• chemical and
• packaging systems.
There is a significant change in controls systems. Relays have increasingly been
replaced by the programmable logic controllers in order to meet the growing
demand for more flexible automation.

Introduction to Electro-pneumatics
In Electro pneumatic controls, mainly three important steps are involved:
• Signal input devices -Signal generation such as switches and contactor, Various types of
contact and proximity sensors
• Signal Processing – Use of combination of Contactors of Relay or using Programmable
Logic Controllers
• Signal Out puts – Out puts obtained after processing are used for activation of solenoids,
indicators or audible alarms
• Command execution: it takes place at high power level either for:
• High speed-fast ejection of product.
• Apply high force as in power presses.

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Introduction to Electro Pneumatics

Signal flow and component of an pneumatic control system

Introduction to Electro Pneumatics

Signal flow and component of an Electro-Pneumatic control system

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Advantages of electro-pneumatic systems

• Greater reliability (Less moving parts subjected to wear)
• Reduced installation complexity (Less components and hoses).
• The control system can be easily modified and adapted (It is easier to change
wiring and modify programs rather than changing mechanical components
and hose networks).
• Environmentally-friendly coupling system (Less lubrication require).
• Lesser installation jobs.
i.e., Electrical control valve, Electrical switches
• Replace tube in pneumatic system to electrical wire in electro-pneumatic
• Less parts are used  Reduce working space.
• Sensor and Controller (such as PLC) can be included in the system

The DC power supply

• It is used to reduce and convert the
230 V AC to a 24 V DC
• It’s components are:
• Transformer
• Rectifier
• Stabilizer

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Criteria for selecting power supplies

• 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.

BASIC ELECTRICAL DEVICES

Seven basic electrical devices commonly used in the control of fluid power
systems are
1. Manually actuated push button switches
2. Limit switches
3. Pressure switches
4. Solenoids
5. Relays
6. Timers
7. Temperature switches

1. Proximity sensors
2. Electric counters

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Push button switches

Push buttons are of two types
• Momentary push buttons return to their unactuated
position when they are released.
• Maintained (or mechanically latched) push buttons
has a latching mechanism to hold it in the selected
position.

Pushbuttons and their symbols

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Pushbuttons and their symbols

Pushbuttons and their symbols

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Limit switches
• A limit switch is an electromechanical device
operated by a physical force applied to it by an
object.
• Limit switches are used to detect the presence or
absence of an object.
• These switches were originally used to define the
limit of travel of an object, and as a result, they
were named Limit Switch.
• The actuation of a limit switch provides an
electrical signal that causes an appropriate
system response.

Limit switches

Cross sectional view of a limit switch

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Pressure switches
• A pressure switch is a pneumatic-to-electric signal converter.

• Pressure switches are used to sense a change in pressure, and opens or closes an
electrical switch when a predetermined pressure is reached.

• Bellow or diaphragm is used to sense the change of pressure. Bellows or

Diaphragm is used to expand or contract in response to increase or decrease of
pressure

Pressure switches

Pressure switch symbols.

Cross sectional view of a pressure switch

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Solenoid DCV
Electrically actuated directional control valves form the interface between the
two parts of an electro pneumatic control. The most important tasks of
electrically actuated DCVs include.
i) Switching supply air on or off
ii) Extension and retraction of cylinder drives
Electrically actuated directional control valves are switched with the aid of
solenoids.

Solenoid DCV
• Solenoid valves perform the same function as normal

pneumatic valves but these are operated electrically.

Open
• Inside the solenoid valve, there is a coil of wire through

which an electric current is passed. It produces a magnetic

field which attracts an iron armature. The movement of Closed

the armature operates the valve.

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Solenoid DCV

Solenoid Operation Off:

• When the electric current is not flowing, a spring

pushes the iron armature out of the coil. A seal
connected to the armature blocks port 1. Air can
flow between ports 2 and 3.

Solenoid DCV

Solenoid Operation On:

• When current flows, the iron armature is attracted

into the coil by a magnetic field. The spring pressure
is overcome and the seal moves to block port 3. Air
can flow between port 1 and 2.

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Solenoid DCV
When the solenoid valve is on, an electric current will flow through the coil.

When current flows through the coil, the iron armature is attracted by magnetism.

The solenoid has control of the valve. Port 1 is connected to port 2 and air flows
to inflate the soft robot.

When the solenoid valve is off, the coil is de-energized and the spring has control

of the valve. Port 2 is connected to port 3 and air flows out of the soft robot

Solenoid DCV

Cross sectional view of a 2/2 way solenoid operated valve

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The symbols for the various solenoid/pilot actuated valves are given in below

3/2 DCV single solenoid with manual

override with spring return
3/2 DCV single pilot operated single
solenoid with manual override with spring
return

5/2 DCV single solenoid with single

manual override with spring return

5/2 DCV double solenoid with double

manual override with spring return
5/2 DCV double pilot operated double
solenoid with double manual override

Various symbols for DCVs

Relays
• A relay is an electro magnetically actuated switch. It is a
simple electrical device used for signal processing.
• When a voltage is applied to the solenoid coil, an
electromagnet field results. This causes the armature to be
attracted to the coil core. The armature actuates the relay
contacts, either closing or opening them, depending on the
design.
• A return spring returns the armature to its initial position
when the current to the coil is interrupted.

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Relays
Some advantages of a relay
• It can be used to switch one or more contacts.
• To switch a high current circuit with a low current circuit

Symbol
Relay Relay block

Relays

A large number of control contacts can be incorporated in relays in contrast to

the case of a push button station.

Relays are usually designated as K1, K2, and K3 etc.

Relays also possess interlocking capability that is an important safety feature in

control circuits.

Interlocking avoids simultaneous switching of certain coils.

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Relays

Cross sectional view of a relay

Animation (Relay OFF)

Source : UniKL Electro-Pneumatic Lecture Note, 2008

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Animation (Relay ON)

Timer Or Time delay relays

Timers are required in control systems to effect time delay between work
operations. This is possible by delaying the operation of the associated control
element through a timer.
Most of the timers we use is Electronic timers.
There are two types of time relay
i) Pull in delay ( on –delay timer)
ii) Drop –out delay (off delay timer)

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Timer Or Time delay relays On-delay timer circuit

• In the on-delay timer, shown in Figure, when push button PB is

pressed (ON), capacitor C is charged through potentiometer R1 as
diode D is reverse –biased. The time taken to charge the capacitor,
depends on the resistance of the potentiometer (R1) and the
capacitance(C) of the capacitor. By adjusting the resistance of the
potentiometer, the required time delay can be set.
• When the capacitor is charged sufficiently, coil K is energised, and its
Off-delay timer circuit
contacts are operated after the set time delay. When the push button
is released (OFF), the capacitor discharges quickly through a small
resistance (R2) as the diode by passes resistor R1, and the contacts
of relay (K) return to their normal position without any delay
• In the off-delay timer, the contacts are operated without any delay
when the push button is pressed (ON). The contacts return to the
normal position after the set delay when the push button is released
(OFF).

Temperature Switch
Temperature switches automatically senses a change in temperature and opens or
closes an electrical switch when a predetermined temperature is reached. This
switch can be wired either normally open or normally closed.
Temperature switches can be used to protect a fluid power system from serious
damage when a component such as a pump or strainer or cooler begins to
malfunction.

Temperature switch symbols.

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