Pneumatics

BITS Pilani Dr.Sachin Waigaonkar

K K Birla Goa Campus
Elements in a Pneumatic System

Hierarchy of
Elements

Flow Control Valve Flow Control Valve

Quick Exhaust Valve Quick Exhaust Valve

Pneumatic Direction Control Pneumatic

Actuation Valve Actuation
[Power Valve]

Direction Control Valves Direction Control Valves

Pressure Sequence Valves Service Unit Pressure Sequence Valves
Pneumatic Timers Pressure Regulator Pneumatic Timers
Dual Pressure [AND] Valves Dual Pressure [AND] Valves
Shuttle [OR] Valves Shuttle [OR] Valves
Limit Switches Limit Switches
Push Buttons Main Air Supply Push Buttons

Low Low
Pressure, High Pressure,
Low Flow Pressure, Low Flow
Rate Zone High Flow Rate Zone
< 4 Bar Rate Zone < 4 Bar
> 4 Bar

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Drawing Pneumatic Circuits

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Port Numbering and Lettering System

Number Letter

1 P Reserved for Pressure Source.

3, 5S, R Reserved for exhaust ports.
2, 4B, A Reserved for output ports.
10 Z
12 Y, Z
14 Z

As a general rule Odd numbers are at the

bottom and Even numbers on the top.

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Directional Control Valves
 Valves control the movement of a
drive unit by controlling the air
flow in and out of it.
 Direction of arrows in the symbol
indicate direction of air flow.
 Number of boxes indicate number
of valve positions.
 The second position from the left
shows default position.
 Each box indicates what the valve
will do when it is in that position.
 In the symbol, all outputs are
shown on the top. Inputs and
exhausts on the bottom. However
the physical location of various
ports on the valve body may be
different.
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An example

Thin brass plates are bent into

U shape in a light tool, with
the aid of a single acting
cylinder. The signal for the
operation is provided by
means of a manual push
button. The piston rod of the
cylinder is at its rear most
end position (bending ram
up) at the time of the start.
PARAMERS:
Cylinder diameter:50 mm,
Stroke: 70 mm.
Operating Pressure:8 bar.

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Internal Construction of
Valves

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Internal Construction of Valves

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5/2 Valve

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Indirectly Activation:
Mechanical

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Direct & Indirect Cylinder
Actuation

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Flow Control

 Some important points about flow control :

 The speed of a cylinder depends upon the rate of flow

of air entering or leaving the cylinder.

 Slowing down the rate of flow of air entering or leaving

a cylinder, slows down cylinder speed.

 Air that is entering the cylinder is known as Supply air,

or Inlet air.

 Air that is leaving a cylinder is known as Exhaust air.

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Flow Control

• Throttles air flow in only one

direction. No control of air
flow in reverse direction.

• Reduces the speed of the

cylinder in only one direction.
Hence two valves are
required to control cylinder
speed in both directions.

• The ball and arrow in the

symbol shows direction of
throttling.

• Offers better flexibility in

speed control.

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One Way Flow Control valve

Arrow shows
direction of
Flow Control
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Flow Control

Forward Motion

Forward speed in a Double

Acting Cylinder may be
controlled by throttling either . .
 Inlet (Supply) air entering the rear side
of the cylinder (Meter-In).

4 2 OR
 Exhaust air leaving the front side of the
cylinder (Meter-Out).

1
Air Pressure
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Inlet Flow Control
Controlling speed in  Air entering the cylinder is throttled, while air
both directions with leaving the cylinder flows at full speed.
Inlet Flow Control
 Forward speed of the cylinder is controlled by
the valve on the rear side of the cylinder.

 Reverse speed is controlled by the valve on the

front side of the cylinder.

 Produces very jerky movement when used with a

constant load. The load moves only after
sufficient pressure is built up inside the cylinder.
The delay in cylinder movement may be very
4 2 substantial with large loads.

 Generally used only in certain clamping

applications where the clamping force must be
1 increased gradually.

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Exhaust Flow Control

• Air leaving the cylinder is throttled, while

air entering the cylinder flows at full speed.

• Forward speed of the cylinder is controlled

by the valve on the front side of the cylinder.

• Reverse speed is controlled by the valve on

the rear side of the cylinder.

• Cylinder moves more smoothly as pressure

inside the cylinder builds up quickly and
4 2 remains constant throughout.

• Better suited to applications where there is a

constant load on the cylinder. Most
commonly used and preferred method of
1
flow control.

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Inlet Flow Control

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Exhaust Flow Control

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Internal Construction of
Valves
Dual Pressure Shuttle
[AND] Valve [OR] Valve

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Internal Construction of
Valves

• Used for Impact applications

or Emergency retraction of
cylinders.

• Provides a shorter and less

complicated path for air to
flow out from a cylinder.

• Cylinder speed increases due

to reduction of resistance to
air flow.

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Internal Construction of
Valves

• Amount of delay
depends on setting of
flow control valve and
size of reservoir.
• Timing starts from the
time the sensing input
[12] receives a signal.
• Timer is reset when
signal to sensing input
[12] is withdrawn.

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Internal Construction of
Valves

• Works as a pressure sensor.

• Produces an output when the
sensing input [12] receives a
signal whose pressure is higher
than the set value.

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Creating 3/2 Valves From 5/2
Valves

Port Port
Blocked Blocked
4 2 4 2

1 1

 A 3/2 Normally Closed valve can  A 3/2 Normally Open valve can be
be created by blocking the created by blocking the normally
normally open port [2]. closed port [4].

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About Practical Sessions-
Componet handling

Mounting Arrangements
for Limit Switches
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Mounting of Components

Press blue lever to mount

Or remove components

Components requiring two

slots for mounting can fall if
not mounted correctly.
e.g. Pneumatic Counter &
Electrical Pressure Switch
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Connecting Tubes

Blocking of two
Press blue ring and connectors
gently pull the tube
to disconnect Blocking a single
connector
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Regulating Pressure

Lift knob to set pressure.

Set pressure to 3 Bar.

If there is no pressure, FIRST
CHECK IF THE COMPRESSOR IS
ON.

Output valve

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Component mounting

No components should be
fixed in front of a cylinder.

All components are

marked with their
respective symbols.

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Cylinder Force Calculations

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Air Consumption Calculations

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Piston Rod Buckling Force
Calculations

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Case-2, Drilling Machine

•. The clamping of a work piece must be separate manual push

buttons from any of the two locations.
•Unclamping must be initiated by a further manual push button.
Other Conditions:
•Clamping must be possible only when a workplace is inserted.
• Un Clamping should not be possible during the drilling
operation.
•It must be possible to set the clamping operation (advance
stroke) to a slow speed.
•Unclamping (return stroke) must be carried out very quickly.

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Positional Sketch

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Case-3

• Billiard balls are distributed from a gravity magazine via

distributor shafts, to two packing stations for individual
packing.
• The signal for the return stroke must be capable of being
given by the machine operator by means of either a manual
push button or a foot operated valve (both are to be provided).
• The advance stroke of the cylinder is triggered automatically
by the piston rod, when the rear most end position is reached.
• PARAMETERS:
• The piston must execute a return stroke only if balls are
present in the gravity magazine.

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Positional Sketch

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Thanks

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