HYDRAULICS & PNEUMATICS

Basic Pneumatic Circuits (1)

Presented by: Dr. Abootorabi

1
Contents
 Introduction
 Symbols
 Circuit layout
 Actuator control 2/2 Valve
 Actuator control 3/2 Valve
 Actuator control 5/2 Valve
 Sequential control
 Sequence solution
 5/3 Valves
2
Introduction

3
Introduction

4
Introduction

5
Introduction

6
Introduction

7
Introduction

8
Introduction

9
Introduction

10
Introduction

11
Introduction

12
Introduction

13
Introduction

14
Introduction
 This module shows the methods A message to pneumatic
of application of pneumatic circuit designers:
valves and components for  Use proven and reliable
control and automation. design techniques
 The methods of pure pneumatic  Produce circuits and
sequential control are confined documentation that are clear
to read
to simple examples.
 Design for safety
 The majority of modern systems
 Do not try to be too clever,
are controlled electronically and
the circuit will be difficult for
is the subject of electro-
others to read and maintain
pneumatic modules.

15
Symbols and Standards in Pneumatics

16
Symbols and Standards in Pneumatics

17
Symbols and Standards in Pneumatics

18
Symbols and Standards in Pneumatics

19
Symbols and Standards in Pneumatics

20
Symbols and Standards in Pneumatics

21
Symbols and Standards in Pneumatics

22
Symbols and Standards in Pneumatics

23
Symbols and Standards in Pneumatics

24
Symbols and Standards in Pneumatics

25
Symbols and Standards in Pneumatics

26
Symbols and Standards in Pneumatics

27
Symbols and Standards in Pneumatics

28
Symbols and Standards in Pneumatics

29
Symbols and Standards in Pneumatics

30
 Circuit layout
 The standard for circuit
diagrams is ISO 1219-2.
 A4 format or A3 folded to A4
height for inclusion in a manual
with other A4 documentation.
 To be on several sheets if
necessary with line
identification code.
 Minimum crossing lines.
 Limit valves position of
operation by actuators shown
by a marker with reference
code to symbol.
 Circuits should be drawn
with all actuators at the top
of the page in order of
sequential operation.
 Other components to be
drawn in sequential order
from the bottom up and
from left to right.
 Circuit should show the
system with pressure applied
and ready to start.
31
 Component identification
 The ISO suggested component  Note: the a0 valve symbol is
numbering system is suited for large drawn in the operated position
circuits and those drawn on several because the actuator A is
pages. instroked.
 For this presentation a simple code a0 a1

A
is used.
 For cylinders: A,B,C etc.
 For associated feedback valves:
2 2
alpha-numeric code ‘a0’ for proof of 12 10 12 10

instroke, ‘a1’ for proof of outstroke. a0 3 1 a1 3 1

 For cylinder B: b0 and b1.

32
 a0 a1 b0 b1 c0 c1
A B C

Sequence
Run/End
A+
B+
B-
C+
C-
A-
Repeat
Run/End

a0 a1 b1 b0 c1 c0

10 bar max 6 bar

To all inlet ports marked

33
Actuator control 2/2
valve

34
 2/2 Valve actuator control
 A pair of the most basic of all valve

types the 2/2 can be used to control

a single acting cylinder.
 The normally closed position of the

valve is produced by the spring. 12

2
10 12
1
10

 The operated position is produced by 1 2

OUT IN
the push button.
 One valve admits air the other valve

exhausts it.

35
 2/2 Valve actuator control
 The button marked OUT is pushed to

operate the valve.

 Air is connected to the cylinder and it

outstrokes.
2 1
 Air cannot escape to atmosphere 12 10 12 10

through the valve marked IN as this is 1 2

OUT IN
closed.
 The air at atmospheric pressure in the

front of the cylinder vents through the

breather port.
36
 2/2 Valve actuator control
 The push button of the valve marked

OUT is released and it returns to a

normal closed position.
 Air is now trapped in the system and

provided there are no leaks and the 2 1

12 10 12 10
piston rod will stay in the outstroked
1 2
position. OUT IN

 If the load increases beyond the force

exerted by the air the piston rod will

start to move in.

37
 2/2 Valve actuator control
 The button marked IN is pushed to

operate the valve.

 Air escapes and the piston rod

moves to the instroked position.

 The push button must be held 2 1
12 10 12 10

operated until the piston rod is fully 1 2

OUT IN
in.
 Atmospheric air will be drawn in to

the front of the cylinder through

the vent port.

38
 2/2 Valve actuator control
 If the button marked IN is

released the piston rod will

remain in the instroked
position.
2 1
12 10 12 10

 Any leaks in the installation 1 2

OUT IN
can cause the piston rod to
creep.

39
 2/2 Valve actuator control
 To control the speed of the piston

rod, flow restrictors are placed in

the pipes close to each of the
valves.

2 1
12 10 12 10
 Adjustment of the restrictors will
1 2
OUT IN
slow down the flow rate thereby
giving independent outstroke and
instroke speed control

40
 2/2 Valve actuator control
 By repeated operation of
either button during
movement, the piston rod
can be moved in small steps
for approximate positioning. 2 1
12 10 12 10

1 2
OUT IN
 This will only be successful

under slow speeds.

41
 2/2 Valve actuator control
 With any compressed air system that

intentionally traps air, the potential

hazard of this must be recognised.

 Unintended release or application of

2 1
12 10 12 10
pressure can give rise to unexpected
1 2
movement of the piston rod. OUT IN

 A pressure indicator or gauge must be

fitted to warn of the presence of

pressure.
42
Actuator control 3/2
valve

43
 3/2 valve actuator control
 A 3 port valve provides the inlet and exhaust path

and is the normal choice for the control of a single

acting cylinder.
 In the normal position produced by the spring, the

valve is closed. 2
12 10
 In the operated position produced by the push
3 1

button the valve is open.

 The push button must be held down for as long as

the cylinder is outstroked.

44
 3/2 valve actuator control
 To generally slow the cylinder speed an

adjustable bi-directional flow regulator or

fixed restrictor can be used.

 The flow regulator setting will be a

2
compromise as the ideal outstroke speed 12 10

may not produce the desired results for 3 1

the instroke speed.

45
 3/2 valve actuator control
 To control the outstroke speed of a single

acting cylinder without controlling the

instroke speed, a uni-directional flow
regulator is used.
 The flow into the cylinder closes the non

return valve and can only pass through the

adjustable restrictor. 12
2
10
 By adjusting the restrictor the outstroke 3 1

speed of the cylinder can be set.

46
 3/2 valve actuator control
 For independent speed control in each direction

two flow regulators are required.

 Installed in opposite directions to each other.

 Upper regulator controls the outstroke speed.

2
12 10
 Lower regulator controls the instroking speed. 3 1

47
Actuator control 5/2 valve

48
 - +
5/2 Valve actuator control
 For a double acting cylinder the power and

exhaust paths are switched simultaneously.

4 2
14 12

 When the button is pushed, the supply at port 1 5 1 3

is connected to port 4 and the outlet port 2

- +
connected to exhaust port 3. The cylinder moves
plus.

 When the button is released port 1 is connected 4 2

14 12
to port 2 and port 4 connected to port 5. The
5 1 3
cylinder moves minus.
49
 - +
5/2 Valve actuator control
 Independent speed control of the plus

and minus movements:

4 2
14 12

5 1 3
 In most applications speed is controlled

by restricting air out of a cylinder. - +

 Full power is developed to drive the

piston with speed controlled by

4 2
restricting the back pressure. 14 12

5 1 3
50
 5/2 Valve actuator control
 Valves with a spring return are mono-stable and

need the operator to be held all the time that the - +

cylinder is required in the plus position.

 Bi-stable valves will stay in the position they were

4 2
last set. 14
12
5 1 3

 The lever valve, example illustrated, indicates a

detent mechanism. The lever need not be held

once the new position has been established.

51
 Manual control
- +
 Remote manual control of a double

acting cylinder:

4 2
14 12
 Valve marked + will cause the cylinder 5 1 3

to outstroke or move plus.

2 2
12 10 12 10
 Valve marked - will cause the cylinder
+ 3 1 - 3 1

to instroke or move minus.

52
 Manual control
 The 5/2 double pilot valve is bi-stable therefore the push button valves

only need to be pulsed.

- + - +

4 2 4 2
14 12 14 12

5 1 3 5 1 3

2 2 2 2
12 10 12 10 12 10 12 10

3 1 3 1 + 3 1 3 1
+ - -
53
 Manual control
 The 5/2 double pilot valve is bi-stable therefore the push button valves

only need to be pulsed.

- + - +

4 2 4 2
14 12 14 12

5 1 3 5 1 3

2 2 2 2
12 10 12 10 12 10 12 10

+ 3 1 - 3 1 + 3 1 - 3 1
54
 Semi-automatic control
- + a1
 Manual remote start of a double A

acting cylinder with automatic return:

4 2
 Cylinder identified as “A”. 14 12

5 1 3

 Trip valve operated at the completion

2 2
of the plus stroke identified as “a1”. 12 10 12 10

+ 3 1 - a1 3 1

55
 Fully-automatic control
- + a0 a1
 Continuous automatic cycling from
A
roller operated trip valves:
 Manual Run and End of the
automatic cycling. 4 2
14 12
 Cylinder will come to rest in the
5 1 3
instroked position regardless of 2
10
when the valve is put to End. 12
Run/End 3 1
 Tags for the roller feedback valves 12
2
10 12
2
10

a0 and a1 show their relative a0 3 1 a1 3 1

positions.

56
Sequential control

57
 Circuit building blocks
a0 a1 b0 b1
A B

Run/End

 These circuits can be considered as building blocks for larger sequential

circuits consisting of two or more cylinders.

 Each actuator will have a power valve and two associated feedback valves.

The first actuator to move also has

a Run/End valve.
58
 Repeat pattern sequence
 A repeat pattern sequence is  The signal starting the first
one where the order of the movement must pass through
movements in the first half of the Run/End valve.

the sequence is repeated in  Needs only the basic building

the second half. blocks to solve.

 Each actuator may have one  Examples of repeat pattern
Out and In stroke only in the sequences:

sequence.  A+ B+ C+ D+ A- B- C- D-

 There may be any number of  A- B+ C- A+ B- C+

actuators in the sequence.  C+ A+ B- C- A- B+

59
 Repeat pattern sequence
a0 a1 b0 b1
A B

Run/End

b0 b1 a1 a0

 The two cylinders A and B are to perform a simple repeat pattern sequence

as follows: A+ B+ A- B-
 Apply the rule “The signal given by the completion of each movement will

initiate the next movement”.

 In this way the roller valves can be identified and labelled.
60
 Repeat pattern sequence
a0 a1 b0 b1 c0 c1
A B C

Run/End

c0 c1 a1 a0 b1 b0

 For three cylinders A, B and C also to perform a simple repeat pattern

sequence as follows: A+ B+ C+ A- B- C-
 Apply the rule “The signal given by the completion of each movement

will initiate the next movement”.

61
 Non-repeat pattern sequence
a0 a1 b0 b1
A B

Run/End

a0 b0 a1 b1

 If the rule applied to a repeat pattern sequence is applied to any other

sequence there will be opposed signals on one or more of the 5/2 valves
preventing operation.
 This circuit demonstrates the problem.

 The sequence is A+ B+ B- A-
62
 Opposed signals
a0 a1 b0 b1
A B

Run/End

a0 b0 a1 b1

 When the valve is set to Run, cylinder A will not move because the

5/2 valve has an opposed signal, it is still being signalled to hold

position by the feedback valve b0.
 If A was able to move + a similar problem will occur for the 5/2 valve

of B once it was +. The sequence is A+ B+ B- A-

63
 Mechanical solution
a0 a1 b0 b1
A B

Run/End

a0 b0 a1 b1

 The problem was caused by valves b0 and a1 being operated at the time

the new opposing instruction is given.

 If these two valves were “one way trip” types and over tripped at the last

movement of stroke, only a pulse would

be obtained instead of a continuous signal.
64
3/2 roller lever valve

Without idle return With idle return (one way trip)

65
3/2 roller lever valve

66
3/2 roller lever valve

67
 Sequence solution methods
 The main solutions to solving  Shift register circuits are similar
sequences are:
to cascade but use one logic
 Cascade (pneumatic)
valve for every step.
 Shift register (pneumatic)
 Electro-pneumatic circuits use
 Electro-pneumatic
 PLC (Programmable logic solenoid valves and electro-
controller) mechanical relays.
 Cascade circuits provide a  PLC: the standard solution for
standard method of solving any
medium to complex sequential
sequence. It uses a minimum of
systems (except where electrical
additional logic hardware (one
logic valve per group of equipment cannot be used).
sequential steps).
68
 Cascade two group
 The A+ B+ B- A- circuit is solved by  Because only one group output is

the two group cascade method. available at a time it is not

 The sequence is divided at the point possible to have opposed signals.
where B immediately returns.  A standard 5/2 double pressure
 The two parts are allocated groups l operated valve is the cascade
and ll. Gp l A+ B+ / Gp ll B- A- valve.
 Two signal supplies are provided
Group l Group ll
from a 5/2 valve, one is available
4 2
14 12
only in group l, the other is available
only in group ll. Select l 5 1 3 Select ll

69
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

70
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

71
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

72
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

73
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

74
Cascade (two group)
a0 a1 b0 b1
A B

b0

a1
Gp l

Gp ll

Sequence:
Run/End Gp l A+ B+ Gp ll B- A-

a0 b1

75
 Cascade building blocks
 A two group building block consists

of a lever valve to run and end the Gp l

sequence plus the 5/2 double pilot

4 2
Gp ll
operated cascade valve. 14 12

 For a two group system consisting 5 1 3 Sel ll

Run/End
2
of any number of cylinders this 10
12
building block and the cylinder 3 1
Sel l
building blocks are all that is
required to solve the sequence.

76
 Cascade rules
 Establish the correct sequence
 Divide the sequence in to groups.
 Always start a sequence with the
Run/End valve selecting group l
e.g.
R/E | A+ B+ | B- C+ | C- A-
 Select the cylinder building blocks.
 Select the cascade building block.
 Interconnect the blocks as follows:
 The first function in each group is
signalled directly by that group
supply.
 The last trip valve operated in each
group is supplied with main supply
air and selects the next group.
 The remaining trip valves are
supplied with air from their
respective groups and initiate the
next function.
 The “run/end” valve will control the
signal from the last trip valve to be
operated.
77
Home Work:
 Question 1:

A+ B+ C+ A- B- C-

 Question 2:

A+ B+ C+ C- B- A-

 Question 3:

A+ A- B+ C+ C- B-

78
Class Work:  Question: A+ B+ B- C+ C- A-

79
 Logic functions &
Feedback methods

80
Logic NOT
 A logic NOT applies to the state of the Z
output when the operating signal is present 10
2
12

(the output is simply an inversion of the X

1 3

operating signal).
 The valve shown is a normally open type

(inlet port numbered 1). Z

 When the signal X is present there is NOT 2
10 12

output Z. X
1 3

 When X is removed output Z is given.

81
Logic MEMORY
 A logic MEMORY allows the output signal

state (ON or OFF) to be maintained after

the input signal has been removed. Z
X
 Any bi-stable valve is a logic MEMORY.
12 10
3 1
 With this lever detented valve, once the Y

lever has been moved X direction or Y

direction it can be released and will stay in
that position.

82
Logic MEMORY
 A bi-stable double pilot valve Z

12
can be set or reset simply by a 10

3 1
pulse (push and release) on

buttons X or Y. 12
2
10
Y
3 1
2
12 10
X
3 1

83
Logic MEMORY (latch)
 A popular memory circuit is the latch.
Z
 Will not re-make after pneumatic power 1 3
Y
failure. 12
2
10

 A pulse on X operates the pilot / spring 12 10

valve to give output Z. 3 1

 A feedback from Z runs through the 2

12 10
normally open valve Y to latch the X
3 1
operation of Z when X is released.
 A pulse on Y breaks the latch and Z is

exhausted.

84
 Logic MEMORY (latch)
Z Z
1 3 1 3
Y Y
12 10 12 10
2 2
12 10 12 10

3 1 3 1

2 2
12 10 12 10
X X
3 1 3 1

85
OR, AND, NOT z 2
OR 12 10

 A single 3/2 pilot operated spring 3 1

return valve can be use for any x y

z 2
AND 12 10
of these logic functions:
3 1
 x OR y gives output z x y

z 2
 x AND y gives output z. NOT 12 10

3 1
 x gives NOT z x

86
Single pulse maker
 Converts a prolonged signal x z

2
12 10
into a single pulse z.
3 1
 Signal x must be removed to

allow the valve to reset then x

x
can be applied again.

 The duration of the pulse can be

adjusted with the flow regulator.

87
 Time delay
 A signal is restricted to slow the rate

of pressure build up on a pressure Output

switch (3/2 differential pressure

2
12 10
operated valve).
3 1
 When the pressure switch operates a

strong un-restricted output is given.

Signal
 A reservoir provides capacitance to in

allow less fine and sensitive settings

on the flow regulator making it easy
to adjust.
88
Time delay
- + a1
 Manual remote start of a
A
double acting cylinder with a
time delay in the outstroked
4 2
position before automatic 14 12

return: 5 1 3

2
12 10

3 1
2 2
12 10 12 10

3 1 a1 3 1

89
Time delay
 Problem:

90
Time delay
 Solution:

91
 ‫‪The end.‬‬

‫‪:‬سعدی (علیه الرحمه)‬

‫‪92‬‬