Slide 1

UNIT 3 INDUSTRIAL PNEUMATICS

BY: [Link]

1
Slide 2
INTRODUCTION

PNEUMATICS derived from PNEUMA - a Greek term that means “breath”

Branch of science which deals with the study of gases especially air, its properties and
application at a pressure higher (compressed) or lower (vacuum) than atmospheric.

Study of air and other gases at rest and in motion, especially under pressure, and
application of that knowledge in the design and control of machines to apply mechanical
force and displacement (work).

Pneumatics is widely used by SMEs for implementing “Low-Cost Automation.”

2
Slide 2
INTRODUCTION

Components
of
Pneumatic Fluid Power system

3
Slide 3
PNEUMATIC SYSTEM

Air from
atmosphere INTAKE
AIR

ACTUATOR
FILTER

V
DC
MANIFOLD
COMPRESSOR

5/2
AIR DRYER
AIR AFTER

L
FR
FILTER

3/2
DCV
COOLER

4
Slide 3 AIR PREPARATION SYSTEM
Stage 1: Inlet Filters
Inlet filters play a crucial role in ensuring that the air entering the
compressor is free of contaminants, which can include dust, dirt, and
other particulates.
Purpose:
To prevent damage to the compressor by filtering out
contaminants from the incoming air.
Types of Filters:
Dry Filters:
• Use disposable cartridges.
• Cartridges are replaced during servicing.
Wet Filters:
• Incoming air passes through an oil bath and a fine wire
mesh filter.
• Dirt particles cling to the oil drops during bubbling.
• Dirt is further removed by the wire mesh as the air passes 5
through.
Slide 3 AIR PREPARATION SYSTEM
Stage 2: Primary Air Treatment
The second stage of the air preparation system is crucial for
ensuring the compressed air is at an appropriate temperature and
humidity level.
Purpose:
To lower the temperature and reduce the humidity of the
compressed air leaving the compressor.
Components Involved:
After cooler
• Aftercooler:
• Lowers the temperature of the compressed air.
• Cooling the air helps in condensing the moisture for
removal.
• Dryer:
• Removes the moisture from the compressed air.
• Ensures the air is dry to prevent any issues caused by Dryer

humidity in the pneumatic system. 6

Slide 3
AIR COMPRESSOR AND AIR RECEIVER SYSTEM
1. Pressure gauge
2. Start/stop switch
3. Auto cut in/out relay
4. Filter
5. Relief valve
6. Drain valve
7. Air receiver
8. Compressor block
9. Flywheel & cooling fan
10. Discharge line
11. Drive belt
12. Guard
13. Motor
14 . Power supply
15. Air supply line

7
Slide 4
AIR COMPRESSOR
Air compressors are devices used to compress atmospheric air
to a high pressure, enabling it to perform work. They function
by:

•Drawing in atmospheric air.

•Compressing the air to increase its pressure.
•Transferring the compressed air into an air receiver.

Air compressors can be powered by either internal combustion

engines (ICE) or electric motors.

8
Slide 4
AIR COMPRESSOR

•An air compressor is a mechanical device that converts

mechanical energy into fluid energy, specifically pressure
energy.
•It increases air pressure by reducing its volume, which also
raises the temperature of the compressed air.
•Selection of a compressor depends on the required operating
pressure and the desired delivery volume. Compressors are
primarily classified into two main types:
a. Reciprocating compressors
b. Rotary compressors

9
Slide 4
SINGLE STAGE PISTON COMPRESSOR

•Piston compressors are the most common type of compressor, with

a basic single-cylinder model illustrated in Figure a.
•During the inlet stroke (Figure a), the piston descends, the inlet
valve opens, and air is drawn into the cylinder.
•As the piston reaches the bottom of the stroke, the inlet valve
closes and the exhaust valve opens, allowing air to be expelled as
the piston rises (Figure b).
•Although Figures suggests that the valves resemble those in an
internal combustion engine, in reality, spring-loaded valves are
used. These valves open and close based on the air pressure acting
on them.

10
Slide 4
SINGLE STAGE PISTON COMPRESSOR

•A single-cylinder compressor produces significant pressure pulses at the

outlet port. While a large receiver can somewhat mitigate this issue, a
multi-cylinder or multi-stage compressor is more commonly used.
•According to the general gas law, compressing a gas results in a
significant rise in temperature.
•In a single-acting compressor, if the exit pressure exceeds about 5 bar,
the compressed air temperature can rise above 200°C, increasing the
motor power required to drive the compressor.
•The maximum pressure achievable in a single-cylinder compressor is 9
bar. For pressures exceeding 9 bar, it is more economical to use a
multistage compressor with cooling between stages.

11
Slide 4
MULTI-STATGE PISTON COMPRESSOR
The figure shows a multistage compressor with an intercooler
between the stages.
In this system, the compressed air from the first stage is
cooled in the intercooler before entering the next stage. The
intercooler serves two main purposes:
• It reduces the temperature of the compressed air during the
compression stages, which is crucial for preventing damage
to the compressor and other mechanical components.
• Cooling the air reduces its volume before it reaches the
second stage of compression, leading to significant energy
savings.
• Typically, two-stage compressors are used for pneumatic
pressures of 10–15 bar. However, multistage compressors
are available for pressures up to around 50 bar.
12
Slide 4 ROTARY COMPRESSORS
Rotary air compressors are a type of compressor that use a
rotary-type positive displacement mechanism. They are
commonly used in various industrial applications due to their
efficiency and reliability. There are several types of rotary air
compressors, including:
Rotary Screw Compressors: These compressors use two
meshing helical screws (rotors) to compress the air. As the rotors
turn, the air is trapped between them, reducing its volume and
increasing its pressure. They are known for their high efficiency,
continuous operation, and ability to handle large volumes of air.
Rotary Vane Compressors: These compressors consist of a rotor
with vanes that slide in and out. As the rotor spins, the vanes trap
air and force it into a smaller space, thereby increasing its
pressure. Rotary vane compressors are compact, reliable, and
suitable for applications requiring steady air flow.
13
Slide 4
ROTARY COMPRESSORS

Scroll Compressors: These compressors have two interleaved spiral

elements, one stationary and one orbiting. The motion of the orbiting
spiral compresses the air trapped in the pockets between the spirals. Scroll
compressors are known for their low noise, high reliability, and efficiency.

Lobe Compressors: Also known as roots blowers, these compressors use

two lobed rotors that rotate in opposite directions. The air is trapped in the
pockets between the lobes and the casing, and then compressed as the
rotors rotate. Lobe compressors are often used for applications requiring
low pressure and high volume.
Each type of rotary compressor has its own advantages and is chosen
based on the specific requirements of the application, such as pressure,
flow rate, and operating environment.
14
Slide 4
SPECIFICATION OF COMPRESSOR
Input volume of Input volume of air Output pressure in
Output pressure in
air in in liter/min pounds per square
bar
cubic foot/min inch (PSI)

Input voltage Loudness of

in volt output sound in
decibel (DB)

Input frequency in
Hertz (Hz)
Input current in
Amp.

Rotating speed of
Output power in
crankshaft in
Horse power (HP) Output power in revolution per
Kilowatt (KW) minute (rpm)

15
Slide 5
AIR RECEIVER
The air is compressed slowly in the compressor. But since the
pneumatic system needs continuous supply of air, this compressed
air has to be stored.
An air receiver tank is an integral and important part of any
compressed air system.
Air receivers, commonly referred to as vessels or tanks are used to
store compressed air before it enters into the piping system and or
equipment.
The air receiver should be large enough to hold all the air
delivered by the compressor.
The pressure in the receiver is held higher than the system
operating pressure to compensate pressure loss in the pipes.

16
Slide 5
AIR RECEIVER
In a compressed air system, a receiver tank provides the following
benefits:

The receiver tank acts as a reservoir of compressed air for peak

demands.

To dry the compressed air by allowing water vapor to

precipitate.

The receiver tank minimizes pulsation in the system caused by

a reciprocating compressor or a cyclic process downstream.

17
Slide 6
AIR PREPARATION

For optimal performance of a pneumatic system, the air must be:

•Clean and dry, free of contaminants and moisture

•Maintained at the specified pressure
•Properly lubricated

• Inadequately prepared compressed air will result in system malfunctions

• Accelerated wear of seals and moving components in cylinders and valves.
• Corrosion of pipes, valves, cylinders, and other components.

18
Slide 6
AIR PREPARATION

The air service unit is a combination of the following :

Air Filter (with water separator)
Air Regulator
Air Lubricator

These functions have often been combined into one unit, i.e. the service unit (FRL UNIT).

FRL units are connected upstream of all pneumatic systems.

19
Slide 6
AIR FILTER
The air filter serves to:
• Prevent solid contaminants from entering the pneumatic
system.
• Condense and remove water vapour present in the
compressed air.

The filter employs a thickened sintered brass cartridge, designed

with a porous structure that creates a zigzag path for airflow,
effectively trapping solid particles.

A deflector cone induces a swirling motion in the incoming air,

leveraging centrifugal force to separate larger contaminants and
water vapour. These are propelled outward, striking the glass
bowl and collecting at the base for removal.
20
Slide 6
AIR FILTER

• A baffle plate is incorporated to prevent turbulent

airflow from splashing water into the filter cartridge.
• Over time, accumulated contaminants and moisture are
removed through either manual or automatic drainage
methods.
• Manual Filter: A drain plug located at the bottom of
the filter bowl allows manual removal of settled water
and solid particles.
• Self-Draining Filter: An automatic float-controlled
valve periodically expels accumulated contaminants
and moisture from the filter.

21
Slide 6
AIR REGULATOR
• The air regulator's primary function is to maintain a
consistent system operating pressure (secondary pressure)
despite variations in the incoming line pressure (primary
pressure).

• It reduces the air supply pressure to the desired level.

• The input (inlet) pressure must always be higher than the

output pressure to ensure proper operation.

• In the pressure regulator (as shown in the referenced

figure), the outlet pressure is detected by a diaphragm
preloaded with a pressure-setting spring.

22
Slide 6
AIR REGULATOR

23
Slide 6
AIR REGULATOR
• Low Outlet Pressure: If the outlet pressure falls below the
desired level, the spring exerts force to displace the diaphragm
and poppet upward, opening the valve to increase airflow and
elevate the outlet pressure.

• High Outlet Pressure: If the outlet pressure exceeds the set

value, the air pressure pushes the diaphragm downward,
reducing the inlet airflow and consequently lowering the outlet
pressure.
• Steady-State Condition: At equilibrium, the valve maintains
a balance between the outlet pressure acting on the diaphragm
and the preset force of the spring, ensuring stable pressure
• regulation.
24
Slide 6
AIR LUBRICATOR
• Compressed air is filtered and regulated before entering the
lubricator, where it mixes with oil to form a fine mist for
lubricating pneumatic system components.

• The lubricator, as shown in the figure, uses the Venturi

principle, increasing air velocity via a pressure differential
between the upper chamber and lower oil reservoir.

• Low pressure in the upper chamber pulls oil through a siphon

tube with a check valve, which controls the oil flow rate.

25
Slide 6
AIR LUBRICATOR
• In the lubricator's throttled zone, high-velocity air breaks oil
droplets into fine particles, creating an air-oil mist.

• A needle valve adjusts the pressure differential between

chambers to control this process.

• Low-viscosity oil produces a finer mist than high-viscosity oil,

ensuring consistent lubrication in the air stream.

26
Slide 6
SERVICE UNIT
• Preparatory functions can be combined into
one unit which is called as ‘service unit’.

• Figure shows symbolic representation of

various processes involved in air preparation
and the service unit.

27
Slide 6
TWIN PRESSURE VALVE/ DUAL PRESSURE VALVE:

Pressure signal applied at Input 1 Pressure signal applied at Input 3 Pressure signal applied at Input 1 and
3

• This valve is pneumatic AND valve. The cross-sectional view of the twin pressure valve
is shown in the figure.
• This valve has two inputs, 1 and 3, and one output, 2.

28
Slide 6
TWIN PRESSURE VALVE/ DUAL PRESSURE VALVE:

In pneumatic logic, a Dual pressure valve works as an AND Truth table

gate. Input 1 Input 3 Output 2
i) If there is no signal at both the inputs , there is also no 0 0 0
output signal. 0 1 0
ii) If only one input signal is applied i.e. either at 1 or 3 , there 1 0 0
will be no output signal at output 2. 1 1 1
iii) If a compressed air signal is applied to input 1 and input 3 0 = No compressed air signal (exhaust or
at the same time, this will produce a signal at output 2. blocked).
1 = Compressed air signal present.
iv) In case of time differences between the input signals, the
signal arriving last reaches the output.
v) In case of pressure differences between the input signals,
the signal with the lower pressure reaches the output.

29
Slide 6
PNEUMATIC CIRCUIT USING AND VALVE:

• In the initial condition, both 3/2 push-button valves

are in their rest position and remain closed, so no air
supply reaches the AND valve, and the cylinder stays
fully retracted.

• When only one push button is pressed, air flows

through just one of the 3/2 valves, supplying pressure
to only one inlet of the AND valve.

• Since the AND valve requires pressure on both of its

inlets simultaneously to operate, no air passes
through to the outlet, and the cylinder does not
extend, which ensures safety.
30
Slide 6
PNEUMATIC CIRCUIT USING AND VALVE

• However, when both push buttons are pressed

together, compressed air flows through both 3/2
valves, supplying pressure to both inlets of the AND
valve at the same time.
• This causes the AND valve to open, allowing air to
pass through its outlet to the single-acting cylinder,
which then extends.
• As soon as either of the push buttons is released, the
air supply to one inlet of the AND valve is cut off,
causing the AND valve to block the flow and vent
the outlet air. This results in the cylinder retracting
automatically under its spring force, completing the
cycle.
31
Slide 6
PNEUMATIC CIRCUIT USING AND VALVE

This setup is widely used as a two-hand safety control

in machines:
• The operator must use both hands to press push
buttons simultaneously to prevent accidental hand
injury.
• The machine will operate (cylinder extends) only if
both hands are away from th danger zone.

32
Slide 6
SHUTTLE VALVE

• This valve is a pneumatic OR valve (also known as a shuttle valve).

The cross-sectional view of the shuttle valve is shown in the figure.
• This valve has two inputs, 1 and 3, and one output, 2.

33
Slide 6 SHUTTLE VALVE

Truth table
In pneumatic logic, a shuttle-valve works as an OR gate.
Input 1 Input 3 Output 2
i) If there is no signal, there is also no output signal.
0 0 0
ii) If compressed air is applied to the first inlet 1, the 0 1 1
valve seat seals the opposing inlet 3, the air flows from 1 0 1
1 to 2. 1 1 1
iii) If compressed air is applied to the second inlet 3, the
0 = No compressed air signal (exhaust or blocked
valve seat seals the opposing inlet 1, the air flows from
3 to 2. 1 = Compressed air signal present.

iv) If signals are present at both inputs, the signal with

the higher pressure reaches the output

34
Slide 6 PNEUMATIC CIRCUIT USING SHUTTLE VALVE

• In the initial condition, both push buttons are in their normal

spring-return position, so no air supply reaches the cylinder,
and it remains in its retracted state.
• When the left push button is pressed, compressed air flows
from Port 1 to Port 2 of the left 3/2 DCV and enters the left
input of the OR valve. The shuttle inside the OR valve shifts
to block the right input, allowing air to pass through the OR
valve output and extend the cylinder piston.
• Once the left push button is released, the left 3/2 DCV
returns to its normal position, and the cylinder exhausts to
the atmosphere through the DCV, causing it to retract.

35
Slide 6 PNEUMATIC CIRCUIT USING SHUTTLE VALVE

• Similarly, when the right push button is pressed,

compressed air flows from Port 1 to Port 2 of the right
3/2 DCV and enters the right input of the OR valve.
• The shuttle shifts to block the left input, allowing air to
flow from the OR valve output and extend the cylinder.
• When the right push button is released, the right 3/2
DCV returns to its normal position, and the cylinder
again exhausts to the atmosphere through the DCV,
retracting the piston.

36
Slide 6 PNEUMATIC CIRCUIT USING SHUTTLE VALVE

Purpose of OR (Shuttle) Valve

• The OR valve ensures that pressing either of the two push
buttons will supply compressed air to the cylinder.
• It acts like a “logical OR gate” – Input A OR Input B →
Output.

37
Slide 6
QUICK EXHAUST VALVE

•This valve is a pneumatic quick exhaust [Link]

cross-sectional view of the quick exhaust valve is shown in the
figure.
•This valve has one input (supply port, typically labelled 1), one
output (cylinder port, typically labelled 2), and one exhaust port
(vent to atmosphere, typically labelled 3).
•When compressed air is applied to input port 1, it pushes an
internal bowl, often shaped like a bat-wing poppet, against
exhaust port 3, effectively blocking it. This allows air to flow
freely from input port 1 through output port 2 to the pneumatic
cylinder (or actuator), causing it to extend or actuate.

38
Slide 6
QUICK EXHAUST VALVE

•When the supply air to input 1 is removed (de-energized), the

seal releases, blocking the path back to input 1 and allowing the
air from the cylinder at output 2 to vent rapidly and directly to
the atmosphere through exhaust port 3 having large area,
enabling quick retraction or reset of the cylinder.
• This design minimizes backpressure and shortens the exhaust
path compared to routing air back through a distant control
valve, significantly speeding up cycle times (often 2-3 times
faster) while reducing air consumption and wear on the system.
• Quick exhaust valves are commonly mounted directly at the
cylinder ports for optimal performance in applications like
automation, assembly lines , and robotics.

39
Slide 6 QUICK EXHAUST VALVE CIRCUIT

Working of the Circuit:

A) Cylinder Extension (Filling Stroke)

[Link] the push button of the 3/2 DCV is pressed:
1. Port 1 (supply) is connected to Port 2 (cylinder line).
2. Compressed air flows from the DCV into Port 1 of the
QEV.
[Link] the QEV:
1. The internal diaphragm/disc moves to block the exhaust
port (3).
2. Air flows freely from Port 1 → Port 2 → Cylinder.
[Link] cylinder extends quickly since it is getting full line
pressure.

40
Slide 6 QUICK EXHAUST VALVE CIRCUIT

B) Cylinder Retraction (Exhaust Stroke)

[Link] the push button is released:
1. The 3/2 DCV returns to its spring-loaded position.
2. Port 2 (cylinder line) is now connected to Port 3 (exhaust) of
the DCV — but the QEV makes this exhaust much faster.
[Link] the QEV:
1. As pressure at Port 1 drops, the higher pressure in the
cylinder pushes the diaphragm/disc toward Port 1.
2. This closes Port 1 and opens Port 3 (exhaust).
3. The air from the cylinder is directly vented to the
atmosphere via Port 3 of the QEV, instead of flowing all
the way back through the DCV.
[Link] reduces the back pressure and makes the cylinder retract
very quickly.
41
 QUICK EXHAUST VALVE CIRCUIT

Purpose of QEV in the Circuit:

• Speeds up the exhaust process → faster return stroke.

• Reduces cycle time for repetitive operations.
• Minimizes pressure losses since air does not travel back
through the valve and long piping.

42
 LOGIC NOT CIRCUIT

In pneumatics, a NOT logic function means that when there is no input

signal, the output is present, and when an input signal is applied, the
output is cut off.

To implement NOT logic, a 3/2 directional control valve (DCV) in

normally open configuration is used.

43
 LOGIC NOT CIRCUIT

Initial State (No Input Signal): INPUT OUTPUT

• The push button is not pressed. 0 1
• The DCV is in its normal position (spring holds it 1 0
there).
• Port 1 (supply) is connected to Port 2 (output).
• The cylinder gets air pressure and extends.
When Input Signal is Given (Push Button Pressed):
• The DCV shifts position.
• Port 2 is now connected to Port 3 (exhaust).
• The supply is cut off, and the air from the cylinder is vented
to atmosphere.
• The spring in the cylinder retracts the piston.
44
 LOGIC NOT CIRCUIT

Initial State (No Input Signal): INPUT OUTPUT

• The push button is not pressed. 0 1
• The DCV is in its normal position (spring holds it 1 0
there).
• Port 1 (supply) is connected to Port 2 (output).
• The cylinder gets air pressure and extends.
When Input Signal is Given (Push Button Pressed):
• The DCV shifts position.
• Port 2 is now connected to Port 3 (exhaust).
• The supply is cut off, and the air from the cylinder is vented
to atmosphere.
• The spring in the cylinder retracts the piston.
45
PNEUMATIC CIRCUIT FOR DIRECT CONTROL OF SINGLE-ACTING CYLINDER

• Single-acting Pneumatic cylinders can be directly controlled

by the actuation of final 3/2 directional control valves (Fig.).
These valves can be controlled manually.

• This type of circuit can be used for small cylinders, as well as

cylinders operating at low speeds with low flow rate
requirements.

• When the 3/2 directional control valve is actuated by a push

button, the valve switches over to the open position, allowing
the working medium into the cylinder. This results in the
forward motion of the piston.

• When the push button is released, the reset spring of the valve
restores the valve to the initial closed position. The cylinder
port is connected to the exhaust por,t and the piston retracts
due to spring action.
46
PNEUMATIC CIRCUIT FOR INDIRECT CONTROL OF SINGLE-ACTING CYLINDER

• This type of circuit (Fig.) is suitable for both large single cylinders and
cylinders operating at high speeds.
• The final pilot-operated 3/2 directional control valve (DCV) is
activated by a normally closed 3/2 push-button valve and can handle
large volumes of air.
• When the push button is pressed, the 3/2 NC valve generates a pilot
signal (12) to the final DCV, which then connects the working medium
to the piston side of the cylinder, causing it to advance.
• When the push button is released, the pilot air from the final valve is
vented to the atmosphere through the 3/2 NC DCV. The signal
pressure required is around 1-1.5 bar.
• The working pressure passing through the final control valve depends
on the force requirement, which is around 4-6 bar.
• Indirect control permits the processing of input signal . Single-piloted
valves are rarely used in applications where the piston has to retract
immediately upon receiving the set pilot signal.
47
PNEUMATIC CIRCUIT FOR DIRECT CONTROL OF DOUBLE ACTING CYLINDER

• Pneumatic double-acting cylinders can be directly controlled by the

actuation of final 5/2 or 4/2 directional control valves (Fig.). These valves
can be controlled manually.

• This type of circuit can be used for small cylinders, as well as cylinders
operating at low speeds with low flow rate requirements.

• When the 5/2 directional control valve is actuated by a push button, the
valve switches over to the open position, allowing the working medium
into the cylinder. This results in the forward motion of the piston.

• When the push button is released, the reset spring of the valve restores the
valve to the initial closed position. The cylinder port is connected to the
exhaust port and the piston retracts due to spring action.

48
PNEUMATIC CIRCUIT FOR INDIRECT CONTROL OF DOUBLE ACTING CYLINDER

• Pneumatic double-acting cylinders can be directly controlled by the

actuation of final 5/2 or 4/2 directional control valves (Fig.). These valves
can be controlled manually.

• This type of circuit can be used for small cylinders, as well as cylinders
operating at low speeds with low flow rate requirements.

• When the 5/2 directional control valve is actuated by a push button, the
valve switches over to the open position, allowing the working medium
into the cylinder. This results in the forward motion of the piston.

• When the push button is released, the reset spring of the valve restores the
valve to the initial closed position. The cylinder port is connected to the
exhaust port and the piston retracts due to spring action.

49