Hydraulics and Pneumatics

Note: 1] On LHS Page Draw Diagram (with pencil & scale) and write Corresponding Description of
Diagram on RHS Page. Strictly follow this point
2] Refer part B for further instructions
Prof.H.N.Deshpande
Title: Design of simple pneumatic systems
Part A Compressed Air Generation and Distribution System
Introduction
Pneumatic technology deals with the study of behavior and applications of compressed air in our daily life in
general and manufacturing automation in particular. Pneumatic systems use air as the medium which is abundantly
available and can be exhausted into the atmosphere after completion of the assigned task.
Basic Components of Pneumatic System

Fig 1: Block Diagram for compressed air generation and distribution system
In pneumatic systems important pat is generation of compressed air, storage of air and distribution of it
to required service unit. Typical pneumatic system consists of following important components:
1] Intake air filters:
To remove dust and dirt from the air so as to protect the system from any damage
2] Compressor and prime mover:
Main function of compressor is to compress the air from atmospheric pressure to required higher operating
pressure. Prime mover like electric motor or internal combustion engine is used to drive the compressor.
3] Receiver tank:
To receive the compressed air from compressor and store it for usage at elevated pressure.
4] FRL unit:
It is service unit. It is combination of filter regulator and lubricator assembly. After FRL unit
compressed air is delivered to accumulator through DCV to complete the required task. In this study we will
consider main components of compressed air generation system and service unit

1] Compressed Air Generation

Compressors are used to produce compressed air from atmosphere. Compressor can be classified on
different categories as under.
PES’s Modern College of Engineering Pune 5 Dept of Mechanical Engg
Hydraulics and Pneumatics

2) Servicing of compressed air:

FRL unit: Need of FILTER REGULATOR LUBRICATOR in pneumatics is completed by combined device
assembly called as FRL unit. Main components of FRL unit are:
A] Air filter:
Air filters are used in a pneumatic system to perform the following main functions:
1. To prevent entrance of solid contaminants to the system.
2. To condense and remove the water vapor that is present in the air passing through it.
3. To arrest any submicron particles that may pose a problem in the system components

The main component of the filter is the filter cartridge which is made mostly of sintered brass, or bronze but
other materials are also used. The thickness of the sintered cartridge helps to provide a random zigzag passage
for the air to flow which in turn, will ensure arrest of the solid particles in the cartridge passage. The water
vapor gets condensed inside the filter and collects at the bottom of the filter bowl which is mostly made of
transparent plastic material for easy visibility.

Fig 2: Air Filter (FRL Unit)

Major part of the bigger foreign particles may also get separated from the air and collect at the bottom of the
bowl. The remaining finer foreign particles move along with the air and pass through the cartridge where these
are arrested as per the filter pore size provided according to the filtration requirement of the system. At the
bottom of the filter bowl, there is an on-off drain valve which could be manually opened to drain off the
accumulated water and other solid particles.

B] Pressure regulator:
Figure 3 shows the internal construction of a pressure regulator in a pneumatic system. The main function of
this valve is to regulate the incoming pressure to the system so that the desired air pressure is capable of flowing
at a steady condition. The valve has a metallic body with the two openings primary and secondary openings.
The adjusting screw will move the diaphragm upward and thus will make the poppet to unseat, thereby creating
an opening to allow air to flow from the primary side to the secondary side. The opening of the valve and
thereby the pressure of air flowing through it, will be directly proportional to the compression of the spring
underneath the diaphragm. Higher the spring compression more will be the amount of opening and hence
greater the pressure and vice versa. So in actual practice, the pressure regulator is but a pressure reducing valve
and has immense application in pneumatic circuits to ensure desired pressure level at various parts of the
system., The valve has two vent-hole openings through which the compressed air is let out into the atmosphere
in case the secondary pressure increases to a level not desirable to the system. The spring at the other side of
the poppet helps to act as a damping device needed to stabilize the pressure.

PES’s Modern College of Engineering Pune 5 Dept of Mechanical Engg

Hydraulics and Pneumatics

Fig 3: Pressure regulator (FRL Unit)

C] Lubricator:
In most of the pneumatic systems the compressed air is first filtered and then regulated to specific
pressure and made to pass through a lubricator in order to form a mist of oil and air for the sole purpose of
lubrication to the mating components of the system.
All lubricators follow the principle of venture meter. the principle of venture meter is shown in Fig 6
where as soon as compressed air flow through throttled zone (B) of pipe(A) pressure differential of is set in due
to this the oil is pushed up to the pipe (E) when air is fed to the oil reservoir (D) through the pipe(C).

Fig 4: Lubricator (FRL Unit)

Part B Design of Pneumatics System
Important Instructions for both problem statements
1] Draw hydraulic circuit fulfilling requirement
2] Select the component from the data attached
3] Write details of component selection (calculation)
4] Attach data table
5] Attach circuit simulation (circuit title, name of student, and roll number)

PES’s Modern College of Engineering Pune 5 Dept of Mechanical Engg

Hydraulics and Pneumatics

1] Design a pneumatic circuit for the following-mentioned application. Consider a simple operation where a double-
acting cylinder is used to transfer parts from a magazine. The cylinder is to be advanced either by operating a push
button or by a foot pedal. Once the cylinder is fully advanced, it is to be retracted to its initial position. A 3/2-way
roller lever valve is to be used to detect the full extension of the cylinder.
Solution
The pneumatic components which can be used to implement the mentioned task are as follows:
1. Double acting cylinder
2. 3/2 push button operated DCV
3. 3/2 roller valve operated DCV
4. Shuttle valve
5. 3/2 foot pedal actuated valve
6. 5/3 pneumatic actuated direction control valve
7. Compressed air source and connecting piping

Figure shows the proposed circuit diagram. As the problem stated, upon actuation of either the push button of
valve (S1) or the foot pedal valve (S2), a signal is generated at 1 or 1(3) side of the shuttle valve. The OR condition
is met and the signal is passed to the control port 14 of the direction control valve (V2). Due to this signal, the left
position of V2 is actuated and the flow of air starts. Pressure is applied on the piston side of the cylinder (A) and the
cylinder extends. If the push button or pedal valve is released, the signal at the direction control valve (V2) port is
reset. Since DCV (V2) is a double pilot valve, it has a memory function which doesn’t allow switching of positions.
As the piston reaches the rod end position, the roller valve (S3) is actuated and a signal is applied to port 12 of the
DCV (V2). This causes actuation of right side of DCV (V2). Due to this actuation, the flow enters at the rod-end side
of the cylinder, which pushes the piston towards left and thus the cylinder retracts.

2] A plastic component is to be embossed by using a die which is powered by a double acting cylinder. The return of
the die is to be effected when the cylinder rod has fully extended to the embossing position and the preset pressure is
reached. A roller lever valve is to be used to confirm full extension. The signal for retracting must only be generated
when the piston rod has reached the embossing position. The pressure in the piston chamber is indicated by a
pressure gauge.
Solution
The pneumatic components to be used to implement this task are:
1. Double acting cylinder
PES’s Modern College of Engineering Pune 5 Dept of Mechanical Engg
Hydraulics and Pneumatics
2. 3/2 push button operated DCV
3. 3/2 roller valve operated DCV
4. shuttle valve
5. 5/3 pneumatic actuated direction control valve
6. pressure sequence valve
7. compressed air source
8. pressure gauge and connecting piping

The proposed pneumatic circuit diagram for embossing application is shown in fig.. When the push button valve
(S1) is pressed, the flow takes place through the valve and a signal is sent to the control port 14 of the direction
control valve (V2). The left position of the direction control valve (V2) is switched-on and the flow enters at the
piston-end of the cylinder (A). It causes the extension of the cylinder. Even if the push button is released the position
of the DCV (V2) will not change due to its memory function. As the piston nears the end position, the roller valve
(S2) is actuated and pressure line is connected to the pressure sequence valve (V1). During the embossing process
the pressure at the piston-side of the cylinder (A) increases. This increase in pressure is indicated by the pressure
regulator (Z1). When the pressure reaches to its pre-set value in the pressure sequence valve (V1), the 3/2 valve of
pressure sequence valve switches and the signal is applied to port 12 of the DCV (V2). The right position of the
DCV is actuated and the piston retracts. During the retracting movement, the roller valve (S2) is released and the
signal at the control port 12 of the DCV (V2) is reset and the pressure sequence valve is also reset.
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PES’s Modern College of Engineering Pune 5 Dept of Mechanical Engg