Basics Of Pneumatics

Ross Controls India

Contents
 Basics
 Introduction
 Air Line Equipment
 Valves

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Basics
Industrial Automation:

Automation

Pneumatics Hydraulics Electrical & Electronics

In most cases low cost automation is achieved by pneumatic systems in reducing Labor cost,
machine investment cost & increasing productivity.

Description of Pneumatics:

In Greek language , “PNEUMA” means Air. The study related to utilization of compressed
air is called as Pneumatics.

A basic pneumatic system consists of following elements:

Compressor Air Signal Elements Control Final Working
Preparation (3/2 way valves) Elements Control Elements
Units (5/2 way) Elements (Actuators)
(FRL’s) (Flow
Control
Valve)
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Basics

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Basics
Pneumatics Equipments:

1. Pneumatic horns
2. Pneumatic Brakes
3. Pneumatic Spray Painting
4. Pneumatic Drills
5. Pneumatic Screw Drivers

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Basics

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Introduction
Compressor installation
 Sizes are defined as follows:
– Small compressors are up to 40 litres per sec and input of no more than 15 kW.
– Medium compressors are between 40 and 300 litres per second and input of between
15 and 100 kW.
– Large compressors anything above the medium limit.
 Typical medium size compressor installation
 Integrated compressor unit including inlet filter, electrically driven compressor, after cooler
and water separator
 Air receiver to smooth demand surges, and provide additional cooling and water collection

Safety valve
Pressure gauge
Distribution pipe
Integrated compressor
and after cooler
SWP
10bar
Isolating valve

Air receiver

Drain valve

Condensate drain
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Distribution
 Main installation
 Dead leg with a drip leg
drain on each corner to
collect and remove water
 Pipes slope to each corner
 FRL units before each
application

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Compressed air quality
ISO 8573-1
Class Solids Oil
particle concentration concentration
size max maximum mg/m 3
µm mg/m 3
1 0.1 0.1 0.01
2 1 1 0.1
3 5 5 1
4 15 8 5
5 40 10 25
6 - - -
7 - - -

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Air Line Equipment
(i) Filters
 To separate and collect
contaminants
 Defector spin the air as
it enters the bowl
 Water droplets and
large solid particles
spun outwards against
bowl and run to the
bottom
 Baffle prevents
turbulent air splashing
water on to the filter
element
 Element traps finer
solid particles

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(ii) Pressure regulator
 Reduces supply pressure P1
to a suitable working
pressure P2
 When there is no flow
demand the poppet valve
closes to hold the pressure
at P2
 Flow demand will open the
poppet valve wide enough to
satisfy the flow rate at
pressure P2
 P2 can be set on a gauge
fitted to the regulator

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Pressure regulator – Working
 To increase pressure P2, pull the adjusting knob
up to disengage the locking teeth
 Turn clockwise until new P2 pressure reached
 The higher spring force pushes the valve open
 The rising pressure P2 acts under the diaphragm
to balance the spring and allow the valve to close
 When the desired pressure is reached the force on
the diaphragm will fully balance the force on the
spring and the valve will close
 Dead end applications are those that are closed
ended. The flow demand is intermittent so the
system will fill and settle at the set pressure.
 While flow is taking place the valve will be held
open wide enough to keep as close to the set
pressure as possible for the flow demand
 As the flow rate increases so the pressure under
the diaphragm decreases to open the valve wider
to maintain the flow close to the set pressure

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Pressure regulator – Working
 This is a relieving regulator to
allow pressure to be reduced to
a lower setting
 Turn anticlockwise to reduce
the spring force
 The higher force under the
diaphragm lifts it clear of the
valve spindle
 P2 can now exhaust until the
diaphragm seals
 Turn clockwise to adjust up to
the new pressure
 Once the desired setting has
been established push down
the locking adjusting knob to
prevent inadvertent changes

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Filter Regulator
• Filter & Regulator
designed as a single unit.
• Air is first filtered then
directed to the primary side
of the regulator
• Pressure is then reduced
to a working value
• Only one unit to install
• Cost saving when
compared to two separate
units

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(iii) Lubricators
 Lubricators are often
referred to as high delivery
units and can be identified
by the green drip rate control
 All of the oil drips seen
through the sight dome enter
the air stream and are
atomised
 The size range of the oil
particles produced are
ideally suited to lubricating
single items of equipment on
medium to short runs of pipe
 The oil particles are carried
along with the air flow, and
gradually "wet out" to
provide adequate lubrication
for applications such as nut
runners, screwdrivers and
other equipment requiring
heavier lubrication

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What is NFPA?

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Pneumatic Valves
 Type of spool valve installation
arrangement

• Type refers to the valves installation arrangement for example

sub-base, manifold, & in-line

In-line Manifold
Sub-base
 Valve Function
• Function is the switching
complexity of a valve
• Shown by two figures 2/2,
3/2, 5/2, & 5/3
• First figure is the number of
main ports. Inlets, outlets,
and exhausts excluding
signal and external pilot
supplies
• Second figure is the number
of states
• A 3/2 valve has 3 ports, and
2 states, normal and
operated.

Pneumatic
symbols
Operators
 An operator is the
mechanism that causes a
valve to change state
Push Mushroom Twist
 They are classified as Button Button
manual, mechanical and
electrical

Key Plunger Roller

Switch Emergency Operated
Stop

Air Pilot Solenoid

Pilot
 Valve Size
• Size refers to a valve’s port • The port size progression
thread. M5, 1/8 , 1/4, 3/8 , 1/2, 3/4, 1”.
• For similarly designed valves
the amount of air flow
through the valve usually
increases with the port size. 3/
M51 8 1/
• Port size alone however /8 2
1/
cannot be relied upon to give 4
a standard value of flow as
this is dependent on the
design of the valve internals. 1 3/
4
Direction control valves
 Spool valves are directional control valves
 Controls the direction of the actuator
 Forward and reverse in case of linear actuator.
 Clockwise and anti clockwise in case of rotary
actuators.
 Actuator Control (3/2 valve)
• A 3 port valve provides the
inlet, outlet and exhaust path
and is the normal choice for
control of a single acting
cylinder Single
• In the normal position Acting
produced by the spring, the
valve is closed 12
2
10
• In the operated position
produced by the push button 3 1
the valve is open
• The push button must be
held down for as long as the
cylinder is outstroked
 Actuator Control (3/2 valve)
• A 3 port valve provides the
inlet, outlet and exhaust path
and is the normal choice for
control of a single acting
cylinder
• In the normal position
produced by the spring, the
valve is closed 12
2
10
• In the operated position
produced by the push button 3 1
the valve is open
• The push button must be
held down for as long as the
cylinder is outstroked
 Actuator Control (5/2 valve)
• A five port valve provides an Double
inlet port 1 that is switched
Acting
between two outlet ports 2
and 4 each with an exhaust
port 3 & 5
• In the normal position
produced by the spring 1 is
4 2
connected to 2 with 4 to
14 12
exhaust 5
• In the operated position 5 1 3
produced by pushing the
button port 1 is connected to
4 with 2 to exhaust 3
 Actuator Control (5/2 valve)
• A five port valve provides an
inlet port 1 that is switched
between two outlet ports 2 and
4 each with an exhaust port 3 &
5
• In the normal position produced
by the spring 1 is connected to
4 2
2 with 4 to exhaust 5
14 12
• In the operated position
produced by pushing the button 5 1 3
port 1 is connected to 4 with 2
to exhaust 3
 Typical Valve
• Identification of the
component parts of a typical 8
7 9
5/2 solenoid valve with
spring return 6
(Sub-base not shown)
– (1) Solenoid (15mm) 5
– (2) Piston
– (3) Spool with disc seals
– (4) Valve body 1

– (5) Return spring

– (6) Alternative ports 2, 4 2
– (7) Pressure indicator
– (8) Manual override 4 3
– (9) Electric connectors
 Spool Types
• A spool has a number of
major and minor diameters
called lands and valleys
• The lands seal with the valve
bore and the valleys connect
valve ports to control flow
direction
• Dynamic seal type has the
seals on the spool
• Glandless type have no
sliding seals
• Static seal type has the
seals fixed in the valve bore
 Disc Seals
• A disc seal is a loose fit in
the groove, with the outer
diameter just in contact with
the valve bore.
• Under differential pressure
the disc seal is pushed
sideways and outwards to
seal the clearance between
the outer diameter of the
piston and the valve bore
• The slim profile gives low
radial force therefore
reducing friction
 Spool Valve (dynamic seals)
• This 5/2 valve has a spool fitted with disc seals
• The seals move with the spool therefore they are called dynamic
• Normal position: port 1 is joined to 2 and 4 is joined to 5
• Operated position: port 1 is joined to 4 and 2 is joined to 3

4 2
14 12

1
5 3

14 12
5 4 1 2 3
 Spool Valve (dynamic seals)
• This 5/2 valve has a spool fitted with disc seals
• The seals move with the spool therefore they are called dynamic
• Normal position: port 1 is joined to 2 and 4 is joined to 5
• Operated position: port 1 is joined to 4 and 2 is joined to 3

4 2
14 12

1
5 3

14 12
5 4 1 2 3
 Spool Valve (glandless)
• This 5/2 valve has a matched spool and sleeve. The fit is so
precise that seals between them are unnecessary
• The tiny amount of air crossing the spool lands provides an air
bearing
• The result is low friction and long life
• Surface finish is up to 2micro Inch

4 2
14 12

5 1 3

14 5 4 1 2 3 12
 Spool Valve (glandless)
• This 5/2 valve has a matched spool and sleeve. The fit is so
precise that seals between them are unnecessary
• The tiny amount of air crossing the spool lands provides an air
bearing
• The result is low friction and long life

4 2
14 12

5 1 3

14 5 4 1 2 3 12
 Spool Valve (static seals)
• This 3/2 valve has a plain spool sliding within static seals
• The O Ring seals are held in carriers fixed in the valve bore and
positioned by spacers (not shown)
• The larger O Rings seal the valve bore with the carriers
• The smaller O Rings seal the carriers with the spool

2
2
12 10

3 1

12 10
 Spool Valve (static seals)
• This 3/2 valve has a plain spool sliding within static seals
• The O Ring seals are held in carriers fixed in the valve bore and
positioned by spacers (not shown)
• The larger O Rings seal the valve bore with the carriers
• The smaller O Rings seal the carriers with the spool

2
2
12 10

3 1

12 10

3 1
 Spool Valve (static seals)
• This 5/2 valve has a plain spool sliding within static seals
• The O Ring seals are held in carriers fixed in the valve bore and
positioned by spacers (not shown)
• The larger O Rings seal the valve bore with the carriers
• The smaller O Rings seal the carriers with the spool

4 2 4 2
14 12

5 1 3

14 12

5 1 3
 Spool Valve (static seals)
• This 5/2 valve has a plain spool sliding within static seals
• The O Ring seals are held in carriers fixed in the valve bore and
positioned by spacers (not shown)
• The larger O Rings seal the valve bore with the carriers
• The smaller O Rings seal the carriers with the spool

4 2 4 2
14 12

5 1 3

14 12
 Balanced Spool
• The pressure acting at any
port will not cause the spool
to move
• The areas to the left and
right are equal and will 14 5 4 1 2 3 12
produce equal and opposite
forces
• Balanced spool valves have
a wide range of application
as any selection of
pressures can be applied to
the 5 ports. Single pressure 14 5 4 1 2 3 12
and twin pressure supply
versions shown
 Three Position Spool Valves
• This type of valve has a
4 2
normal state where the spool
is in a mid position
5 1 3
• The characteristic in the
centre position is determined
4 2
by the land spacings on the
spool
5 1 3
• The three types are:
All ports blocked
Open exhausts 4 2

Open pressure
5 1 3
 5/3 Valve (all ports sealed)
 With the spool in the mid (normal) position all ports are sealed
 Spool right, port 1 is joined to 4, port 2 is joined to 3
 Spool left, port 1 is joined to 2, port 4 is joined to 5

4 2

5 1 3

14 12
5 4 1 2 3
 5/3 Valve (all ports sealed)
 With the spool in the mid (normal) position all ports are sealed
 Spool right, port 1 is joined to 4, port 2 is joined to 3
 Spool left, port 1 is joined to 2, port 4 is joined to 5

4 2

5 1 3

14 12
5 4 1 2 3
 5/3 Valve (all ports sealed)
 With the spool in the mid (normal) position all ports are sealed
 Spool right, port 1 is joined to 4, port 2 is joined to 3
 Spool left, port 1 is joined to 2, port 4 is joined to 5

4 2

5 1 3

14 12
5 4 1 2 3
Logic “OR” Shuttle Valve
 An air signal given to either the
2
left hand port 1 or the right
hand port 1 will result in an 1 1
output at port 2 2
 The sealing disc moves across
to seal the exhaust signal line
to prevent loss of signal
pressure
1 1
2

1 1
Logic “AND” Shuttle Valve
 A single air signal at either of
2 2
the ports 1 will cause the
shuttle to move and block the 1 1 1 1
signal ISO 1219-1 Popular old
 If a signals are applied at both symbol symbol
the left hand AND right hand
ports 1 only one of them will be 2 2
blocked the other will be given
as an output at port 2
1 1 1 1
 If the pressures are not equal 2 2
the one with the lowest
pressure is switched
1 1 1 1
 Quick Exhaust Valve
 In some applications cylinder
speed can be increased by
50% when using a quick
exhaust valve
 When operated, air from the
front of the cylinder
exhausts directly through the
quick exhaust valve
 The faster exhaust gives a
lower back pressure in the
cylinder therefore a higher
pressure differential to drive
out the piston rod
 Quick Exhaust Valve
 Port 2 is connected directly
2
to the end cover of a cylinder 1

 Port 1 receives air from the

control valve
 Air flows past the lips of the 2
seal to drive the cylinder
 When the control valve is
exhausted, the seal flips to
the right opening the large
direct flow path
 Air is exhausted very rapidly
1
from the cylinder for
increased speed
 Quick Exhaust Valve
 Port 2 is connected directly
2
to the end cover of a cylinder 1

 Port 1 receives air from the

control valve
 Air flows past the lips of the 2
seal to drive the cylinder
 When the control valve is
exhausted, the seal flips to
the right opening the large
direct flow path
 Air is exhausted very rapidly
1
from the cylinder for
increased speed
 Guide to Valve Size and Flow
 This graph gives a guide to the to flow range appropriate to
different valve sizes
 Port size alone can only be a rough guide, individual valve types
will vary according to design
 The flow values indicated by the vertical lines are
at P1 = 6 bar, with 1bar pressure drop

1”
3/
4
1/
Valve 2
3
size 1/8
/4
1/
8
M5

250 1250 2500 4250 6000 10000

750
Flow l/min
 Flow Regulation
 By the use of flow regulators
the outstroke speed and
instroke speed of a piston
rod can be independently
adjusted
 Speed is regulated by
controlling the flow of air to
exhaust
 The front port regulator
controls the outstroke speed
and the rear port regulator
controls the instroke speed
 Flow Regulator
 Uni-directional, line mounted
adjustable flow regulator
– Free flow in one direction
– Adjustable restricted flow in
the other direction
 Flow Regulator
 Uni-directional, line mounted
adjustable flow regulator
– Free flow in one direction
– Adjustable restricted flow in
the other direction
 Banjo Flow Regulator
 Designed to fit directly in to
cylinder ports, so placing
adjustment at the
appropriate cylinder end
 Two types:
– One to give conventional
flow restriction out of the
cylinder and free flow in (as
illustrated)
– The other type to give
restricted flow in to the
cylinder and free flow out
(not illustrated)
Actuators
Pneumatic Actuator - Construction
Single Acting Cylinder

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Double Acting Cylinder

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Rotary Actuator

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Thank You

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