INTRODUCTION TO

PNEUMATIC SYSTEM
BASIC COMPONENTS OF PNEUMATIC
SYSTEMS
• Inlet filter
• Air compressor
• Air cooler
• Storage / Reservoir
• Air dryer
• FRL UNIT
• Control valves
• Actuator
CIRCUIT DIAGRAM
 ADVANTAGES OF PNEUMATIC SYSTEM

• Pneumatic Systems are light in weight.

• Operating elements are cheaper and easy to
operate
• Power losses are less due to low viscosity of air
• High output to weight ratio
• Pneumatic systems offers a safe power source in
explosive environment
• Leakage is less and does not influence the
systems. Moreover, leakage is not harmful
• High adaptability to harsh environment -Compared
to the elements of other systems, compressed air is less
affected by high temperature, dust, corrosion, etc.
• Environmental friendly - The operation of pneumatic
systems do not produce pollutants. The air released is
also processed in special ways. Therefore, pneumatic
systems can work in environments that demand high
level of cleanliness. One example is the production lines
of integrated circuits.
• Economical - As pneumatic components are not
expensive, the costs of pneumatic systems are quite low.
Moreover, as pneumatic systems are very durable, the
cost of repair is significantly lower than that of other
systems.
LIMITATIONS OF PNEUMATIC SYSTEMS
• Relatively low accuracy - As pneumatic systems are powered by the
force provided by compressed air, their operation is subject to the
volume of the compressed air. As the volume of air may change
when compressed or heated, the supply of air to the system may not
be accurate, causing a decrease in the overall accuracy of the
system.
• Low loading -As the cylinders of pneumatic components are not
very large, a pneumatic system cannot drive loads that are too
heavy.
• Processing required before use - Compressed air must be processed
before use to ensure the absence of water vapour or dust. Otherwise,
the moving parts of the pneumatic components may wear out
quickly due to friction.
• Uneven moving speed - As air can easily be compressed, the
moving speeds of the pistons are relatively uneven.
• Noise -Noise will be produced when compressed air is released
 Comparison of Electrical,
mechanical,pneumatic and hydraulic
transmission systems
 AIR FILTERS
• Function Of Air Filters -
To remove all foreign matter and allow dry and
clean air flow without restriction to regulator and
then to the lubricator
To condensate and remove water from the air
To arrest fine particles and all solid contaminants
from air
 Construction
• The construction of typical cartridge type filter
along with graphical symbols is shown in
Figure.
• It consists of filter cartridge, Deflector, bowl,
water drain valve.
• Filter bowl is usually made of plastic and
transparent.
• For pressure more than 10 bar, bowl may be
made of brass.
 Operation
• Air enters the inlet port of the air filter through angled louvers. This
causes the air to spin as it enters the bowl.
• The centrifugal action of the rotating air causes the larger pieces of dirt
and water particles to be thrown against the inner wall of the filter
bowl. These contaminants then flow down into the bottom of the filter
bowl.
• A baffle prevents turbulent air from splashing water on to the filter
element.
• The air, which has been pre-cleaned in this way, then passes through
the filter element, where the fine dirt particles are filtered out.
• The size of the dirt particles which can be filtered out depends on
mesh size of filter element (usually 5-50 microns).
• The compressed air then exits through the outer port.
• The pressure difference between inlet and outlet will indicate the
degree to which the filter element is clogged
 AIR REGULATOR
• Function:
 The function of the air pressure regulator is to maintain
working pressure virtually constant regardless of
fluctuations of the line pressure and air consumption.
 When the pressure is too low, it results in poor
efficiencies and when the pressure is too high, energy is
wasted and equipment’s performance decay faster.
 In pneumatic system, pressure fluctuations occur due to
variation in supply pressure or load pressure.
 It is therefore essential to regulate the pressure to match
the requirement of load regardless of variation in supply
pressure or load pressure.
Relieving or Venting Type Diaphragm Pressure
Regulator (pressure reducing valve)
• A Relieving type pressure regulator is shown in
Figure.
• Outlet pressure is sensed by a diaphragm
preloaded with a adjustable pressure setting spring.
The compressed air , which flows through a
controlled cross section at the valve seat, acts on
the other side of the diaphragm.
• The diaphragm has large surface area exposed to
secondary (outlet) pressure and is quite sensitive to
its fluctuations. The movement of diaphragm
regulates the pressure.
 WORKING
• If the outlet pressure is low:
 whenever the more compressed air is consumed
on secondary side or load side, then load pressure
reduces.
 Therefore less force acts on diaphragm.
 The opposing higher spring force pushes the
diaphragm in such a way as to move the valve disc
more and permitting more air to flow to secondary
side and thus increasing the pressure again.
• If the outlet pressure is high:
 whenever the less compressed air is consumed
on secondary side or load side, then load
pressure increases.
 Therefore more force acts on diaphragm. The
opposing higher spring force pulls down the
diaphragm in such a way as to move the valve
disc less and permitting air to flow to vent hole
and thus decreasing the pressure again
 AIR LUBRICATOR
• Function:
 The function of air lubricator is to add a controlled
amount of oil with air to ensure proper lubrication
of internal moving parts of pneumatic components.
 Lubricants are used to :-
o To reduce the wear of the moving parts
o Reduce the frictional losses
o Protect the equipment form corrosion
 Operation
• Schematic diagram is shown in Figure.
• As air enters the lubricator its velocity is
increased by a venture ring.
• The pressure at the venture ring will be lower
than the atmospheric pressure and the pressure on
the oil is atmospheric.
• Due to this pressure difference between the upper
chamber and lower chamber, oil will be drawn up
in a riser tube.
• Oil droplets mix with the incoming air and form a
fine mist.
• The needle valve is used adjust the pressure
differential between across the oil jet and hence the
oil flow rate.
• The air – oil mixture is forced to swirl as it leaves
the central cylinder so that large particles of oil is
goes back to bowl and only the mist goes to outlet.
• The lubricator starts to operate only when there is
sufficient flow of air. If too little air is drawn off, the
flow velocity at the nozzle is not sufficient to
produce an adequate vacuum and hence to draw oil
out of the vessel.
 AIR COMPRESSORS
• A Compressor is a machine that compresses the air or
another type of gas from a low inlet pressure (usually
atmospheric pressure) to a higher desired pressure level.
• Compressor increases the pressure of the air by reducing its
volume.
• Work required for increasing pressure of air is generally,
electric motor, internal combustion engine or steam engine,
turbine etc. are used as prime movers.
• Compressors are similar to fans and blowers but differ in
terms of pressure ratios.
• Fan is said to have pressure ratio up to 1.1 and blowers
have pressure ratio between 1.1 to 4 while compressors
have pressure ratios more than 4.
 COMPRESSORS CAN BE CLASSIFIED IN THE
FOLLOWING DIFFERENT WAYS
• Based on principle of operation:
Positive displacement compressor.
Non-positive displacement compressors.
• Based on number of stages:
Single stage Compressor, for delivery pressure upto 5 bar.
Two stage Compressor, for delivery pressure between 5 to
35 bar
Three stage Compressor, for delivery pressure between 35
to 85 bar.
Four stage compressor, for delivery pressure more than 85
bar
• Based on Capacity of compressors:
Low capacity compressors, having air delivery capacity of 0.15
m3/s or less
Medium capacity compressors, having air delivery capacity
between 0.15 to 5 m3/s.
High capacity compressors, having air delivery capacity more
than 5 m3/s
• Based on highest pressure developed:
Low pressure compressor, having maximum pressure upto 1 bar
Medium pressure compressor, having maximum pressure from 1
bar to 8 bar
High pressure compressor, having maximum pressure from 8 to
10 bar
Super high pressure compressor, having maximum pressure
more than 10 bar.
 POSITIVE DISPLACEMENT COMPRESSOR
• In positive displacement compressors the
compression is realized by displacement of solid
boundary and preventing fluid by solid boundary
from flowing back in the direction of pressure
gradient.
• Due to solid wall displacement these are capable of
providing quite large pressure ratios.
• Positive displacement compressors draw in and
capture a volume of air in a chamber, then reduce
the volume of the chamber to compress the air.
 NON-POSITIVE DISPLACEMENT
COMPRESSORS
• Non-positive displacement compressors also called as
steady flow compressors use dynamic action of solid
boundary for realizing pressure rise.
• Here fluid is not contained in definite volume and
subsequent volume reduction does not occur as in
case of positive displacement compressors.
• Rather than physically reducing the volume of a
captured pocket of air, dynamic compressors instead
speed up the air to high velocity, and then restrict the
air flow so that the reduction in velocity causes
pressure to increase.
 Single stage reciprocating Compressor
• Construction:
Piston type compressor consists of cylinder, cylinder head,
and piston with piston rings, inlet and outlet spring loaded
valves, connecting rod, crank crankshaft and bearings.
• Operation
Compression is accomplished by the reciprocating
movement of a piston within a cylinder. This motion
alternately fills the cylinder and then compresses the air. A
connecting rod transforms the rotary motion of the
crankshaft into the reciprocating motion of piston in the
cylinder. Depending on the application, the rotating crank
(or eccentric) is driven at constant speed by a suitable
prime mover (usually electric motor).
 WORKING
• Inlet stroke: -
suction or inlet stroke begins with piston at top dead centre (a position
providing a minimum or clearance volume). During the downward stroke,
piston motion reduces the pressure inside the cylinder below the
atmospheric pressure. The inlet valve then opens against the pressures of
its spring and allows air to flow into the cylinder. The air is drawn into the
cylinder until the piston reaches to a maximum volume position (bottom
dead centre).The discharge valve remains closed during this stroke
• Outlet stroke:
During compression stroke piston moves in the opposite direction
(Bottom dead centre to top dead centre), decreasing the volume of the air.
As the piston starts moving upwards, the inlet valve is closed and
pressure starts to increase continuously until the pressure inside the
cylinder is above the pressure of the delivery side which is connected to
the receiver. Then the outlet valve opens and air is delivered during the
remaining upward motion of the piston to the receiver.
 MULTI STAGE PISTON COMPRESSOR
• As per general gas laws, if the pressure increases
temperature also increases.
• For example : if the exit pressure of compressor is 5
bar in a single acting compressor, the compressor air
temperature can rise to over 200 and the motor power
needed to drive the compressor rises.
• Therefore single stage compressors are not used for
high pressures.
• Multistage compressors are used when high pressures
are required, because better cooling between stages can
effectively increase the efficiency and reduce the input
power requirements.
 Working:
• Figure shows the two stage reciprocating air
compressor.
• When the prime mover connected to crank shaft
rotates, crank rotates and the piston in the first stage
reciprocates.
• It sucks the air through the suction filter and inlet
valve. The air, compressed to a certain degree
passes from the left cylinder to right cylinder
through the intermediate cooler.
• The compression ratio in the first stage is
determined by the degree of cooling required.
• Figure shows various parts of three stage (V type)
reciprocating air compressor with receiver (air
tank).
• The pressure switch is connected to the electric
motor.
• When the desired pressure in the air tank is
reached it stops the motor and hence the
compressor.
• The safety valve opens when the pressure in air
tank exceeds the set safe pressure.
• The drain valve drains the condensate produced at
the condenser and the receiver.
• Cylinders and intercoolers are either air cooled
(with fins) or water cooled (with water jackets in
the cylinder).
• Air cooled compressor are used for low pressure
applications and water cooled compressors are
used for high pressure applications.
 Advantages Of Piston Type Compressor
 Piston type compressors are available in wide
range of capacity and pressure
 Very high air pressure (250 bar) and air volume
flow rate is possible with multi-staging.
 Better mechanical balancing is possible by
multistage compressor by proper cylinder
arrangement.
 High overall efficiency compared to other
compressor
Disadvantages Of Piston Type Compressor
• Reciprocating piston compressors generate
inertia forces that shake the machine. Therefore
, a rigid frame, fixed to solid foundation is
often required
• Reciprocating piston machines deliver a
pulsating flow of air. Properly sized pulsation
damping chambers or receiver tanks are
required.
• They are suited for small volumes of air at high
pressures.
DIAPHRAGM TYPE COMPRESSOR
ROTARY VANE COMPRESSOR
• Sliding vane compressors are rotary positive
displacement compressors.
• A slotted cylinder is fitted with non-metallic
vanes and placed eccentric inside a tube.
• As the slotted cylinder is turned, the vanes
slide along the inner wall of the tube forming
regions of changing volume.
 LIQUID RING COMPRESSORS
• Liquid ring compressors utilize a squirrel cage fan
type impeller which is placed eccentric inside a
tube .
• A compatible liquid is introduced into the chamber
along with the gas to be compressed.
• Because of the centrifugal force and the shape of
the internal cavity, the liquid forms an eccentric
shape producing regions of changing volume.
• The liquid must be separated from the compressed
gas after the compression process and recirculated.
 TWIN LOBE COMPRESSOR
• Two straight mating lobed impellers trap the gas and
carry it from intake to discharge .
• There is no internal compression.
• They consist of a pair of lobes, rotating inside a
properly shaped casing, closed at ends by side plates.
• The drive lobe is connected to the driven lobe,
through a pair of gears & they always rotate in
opposite directions.
• As the rotors rotate, air is drawn into inlet side of the
cylinder casing & forced out from the outlet side
against the system pressure.
• There is no change in the volume of air within
the machine but it merely displaces the air from
the suction end to the discharge end, against the
discharge system resistance.
• They are ideal for applications requiring Constant
Flow Rate at Varying Discharge Pressures.
 SCREW COMPRESSOR
• Figure of the two screws within the body of a screw
compressor: a female and a male screw. The female screw has
inlets and the male screw has convex helical inlets. The screws
rotate in opposite directions with the female screw receiving
the driving power and transmitting this power to the male
screw through a set of synchronization gears.
• As the screws rotate, the gas is drawn into the inlet port and
fills up the space between the screws. The compression begins
when the end of a male thread blocks the end of a female
thread. The volume available between the compressor body
and these two threads then progressively decreased during
rotation. When this volume merges into the delivery outlet of
the compressor, compressed gas is discharged from the
compressor.
 Centrifugal Compressors
• Centrifugal compressors are dynamic machines in
which the rapidly rotating impeller accelerates the
gas .
• The process flow propagates from axial to radial
(perpendicular to shaft center line) into a stationary
diffuser converting velocity to pressure.
• Centrifugal compressors use a rotating disk
or impeller in a shaped housing to force the gas to the
rim of the impeller, increasing the velocity of the gas.
• A diffuser (divergent duct) section converts the
velocity energy to pressure energy.
 OPERATION:
• Air enters the compressor at the suction inlet.
• The impeller accelerate the gas. The centrifugal
compressor has one moving element”the impeller on the
driveshaft”.
• The impeller discharges the gas to a diffuser.
• The diffuser is a circular,narrow chamber.
• A back pressure is created in the impeller due to the
acceleration.
• The gas velocity increases in the diffuser.
• As the gas speed slows in the volute , the kinetic energy is
converted into pressure.
• The compressed gas exits at the discharge line
 AIR RECEIVER
• Receivers perform several functions in compressed air systems.
• they provide a larger system capacity.
• The receiver also dampens pulsations from reciprocating
compressors, acts as a reservoir to prevent excessively
temporary pressure drop during sudden short-term demand, and
can be used to smooth air flow through dryers, separators and
other air conditioning equipment.
• Because the air entering the receiver is reduced in velocity and
cooled, some of the moisture may condensate and fall to the
bottom of the receiver where it can be removed by a valve or
preferably, a trap. Such a receiver can reduce further the amount
of moisture which must be removed by a subsequent drying
stage.
• The receiver always equipped with a pressure relief valve.
• Figure shows essential features of a receiver. They
are usually of cylindrical construction fabricated out
of steel.
• Receiver is basically a pressure vessel and attracts the
safety of testing requirement as per factory act.
• A safety valve is necessary to release the excess
pressure of air stored.
• A pressure gauge and temperature gauges are
provided and usually coupled with pressure switches
to control on-off of the compressor and for remote
alarms.
• A drain cock allows removal of condensed water.
Access via a manhole allows cleaning.
CONTROL VALVES
5/2 DCV
Time delay valve
 Shuttle valve
• It is also known as a double control valve or
double check valve.
• A shuttle valve has two inlets and one outlet.
• At any one time, flow is shut off in the direction
of whichever inlet is unloaded and is open from
the loaded inlet to the outlet.
• A shuttle valve may be installed, for example,
when a power unit (cylinder) or control unit
(valve) is to be actuated from two points, which
may be remote from one other.
 Quick Exhaust Valves
• A quick exhaust valve is a typical shuttle valve.
• The quick exhaust valve is used to exhaust the cylinder air
quickly to atmosphere.
• In many applications especially with single acting
cylinders, it is a common practice to increase the piston
speed during retraction of the cylinder to save the cycle
time.
• The higher speed of the piston is possible by reducing the
resistance to flow of the exhausting air during the motion of
cylinder.
• The resistance can be reduced by expelling the exhausting
air to the atmosphere quickly by using Quick exhaust valve.
• The construction and operation of a quick exhaust valve is shown in
Figure .
• It consist of a movable disc (also called flexible ring) and three ports
namely, Supply port 1, which is connected to the output of the final
control element (Directional control valve).
• The Output port, 2 of this valve is directly fitted on to the working
port of cylinder. The exhaust port, 3 is left open to the atmosphere
• Forward Motion: During forward movement of piston, compressed
air is directly admitted behind the piston through ports 1 and 2 Port 3
is closed due to the supply pressure acting on the diaphragm. Port 3 is
usually provided with a silencer to minimise the noise due to exhaust.
• Return Motion: During return movement of piston, exhaust air from
cylinder is directly exhausted to atmosphere through opening 3
(usually larger and fitted with silencer) .Port 2 is sealed by the
• diaphragm. Thus exhaust air is not required to pass through long and
narrow passages in the working line and final control valve
 Twin Pressure Valve
• This valve is the pneumatic AND valve. It is also derivate of
Non Return Valve.
• A two pressure valve requires two pressurised inputs to
allow an output from itself.
• The cross sectional views of two pressure valve in two
positions are given in Figure.
• As shown in the figure, this valve has two inputs 12 and 14
and one output 2.
• If the compressed air is applied to either 12 or input 14, the
spool moves to block the flow, and no signal appears at
output 2.
• If signals are applied to both the inputs 12 and 14, the
compressed air flows through the valve, and the signal
appears at output 2.
 PNEUMATICS ACTUATORS
• Pneumatic actuators are the devices used for
converting pressure energy of compressed air
into the mechanical energy to perform useful
work.
TYPES OF PNEUMATICS ACTUATORS

i) Linear Actuator or Pneumatic cylinders

ii) Rotary Actuator or Air motors
Types of Pneumatic cylinders /Linear actuators

1. Based on application for which air cylinders

are used
i) Light duty air cylinders
ii) Medium duty air cylinders
iii) Heavy duty air cylinders
2. Based on the cylinder action
i) Single acting cylinder
ii) Double acting cylinder
3. Based on cylinder’s movement
i) Rotating type air cylinder
ii) Non rotating type air cylinder
4. Based on the cylinder’s design
i) Telescopic cylinder
ii) Tandem cylinder
iii) Rod less cylinder
 Cable cylinder,
 Sealing band Cylinder with slotted cylinder barrel
 Cylinder with Magnetically Coupled Slide
iv) Impact cylinder
v) Duplex cylinders
vi) Cylinders with sensors
 SINGLE ACTING CYLINDERS.
• In single acting cylinder, compressed air is fed
only on one side. Hence this cylinder can
produce work only in one direction.
 Telescopic Cylinder
• Extension stroke:
• When the pressure is applied at port A, air flow through
port X and Y and pressure is applied on both sides of
Piston 1. But difference in areas causes the piston 1 to
move to the right. Once the piston 1 fully extends, Inner
Piston 2 will extend.
• Retraction stroke:
• To retract, air is applied to port B. Air pressure will act on
the annulus of the inner piston 2 and moves inner piston 2
to the left. When the inner piston moves to left and started
to close port X, air from port B goes to annular side of the
piston 1 via port Y and pushes the piston 1 to the left.
 TANDEM CYLINDERS
• Tandem cylinders are two separate double acting air
cylinders arranged in line to one cylinder body so that
the power generated by the two is added together,
thereby approximately doubling the piston output.
• A tandem cylinder is used in applications where a
large amount of force is required from a small-
diameter cylinder.
• Basically, a tandem cylinder is simply two or more
separate cylinders stacked end to end in a unit and
with all the pistons mounted on a common piton rod.
 Cable Cylinder
• It is used for very long strokes, up to 2000mm. It consists of
nylon jacketed cable which enters the cylinder barrel and is
attached to one end of internal cylinder and exits through
• the gland seal and enters into the other end of the internal
cylinder through the another gland seal.
• When compressed air enters the cylinder the piston moves
from end-to-end. The cables which are attached to either
side of the piston and extend out the ends of the cylinder
move as well.
• Depending on the direction of the piston both the carriage
and any on-carriage tooling moves towards one end of the
air cylinder or the other.
 CYLINDER MOUNTINGS.
1. Fixed Centreline mountings
2. Pivoted centreline mountings
3. Fixed non centreline mountings
• Fixed Centreline mountings:
• In this mounting, the cylinder is supported along its centre line.
The mounting bolts are thus subjected to shear or simple stress.
This mounting needs accurate alignment.Misalignment is not
tolerable.
• Pivot centreline mounting:
• Many applications need rotational degree of freedom for a
cylinder as it reciprocates. The pivot mounting can be clevis type
or trunnion type. This mounting permits rotational freedom in one
plane. If universal joint is used, greater degrees of freedom are
possible.
• Fixed non centreline mounting:
• This mounting of cylinder introduces torque under loaded
condition. The cylinder may rotate or bend about its mounting bolt
when loaded. The stress level on the cylinder is higher as
compared to the centre line mounting.
Classification according to construction

• Flanged type cylinders

• One piece welded construction
• Threaded end cylinders
• Tie rod type
Tie-rod cylinders
• Tie-rod cylinders have square or rectangular
end caps secured to each end of the barrel by
rods that pass through holes in the corners of
the end caps. Nuts threaded onto the end of
each tie rod secure the end caps to the barrel.
Static seals in the barrel/end-cap interface
prevent leakage.
 Air motors
• Vane motors
• Turbine motors
• Piston motors
• Gerotor (same as twin twin lobe)
Vane motors