Electro-Pneumatics

Module 1
Introduction to
Electro-pneumatics
 Module Objectives
After the completion of this module,
the student will be able to:
1- Explain all safety precaution when
working with electro-pneumatics.

2- Explain the concept of signal flowing in

electro-pneumatics.

3- Identify the advantages and

disadvantages of the electro-pneumatics.
 Module Contents
1. Introduction to electro-pneumatics
2. Signal flow in electro-pneumatics
3. Advantages of electro-pneumatic systems
4. Components of electro-pneumatic system
5. Safety and operation
6. Practical task
7. Practical task
8. Practical task
 Uses of Electro-Pneumatics
Widely used in many areas of
• Industrial automation.
• Production,
• assembly,
• packaging systems
Examples of applications are:
•Milk filling machine
•Yogurt filling machine
 Electro-Pneumatics
It’s components are controlled by:
• Electrical and electronic circuits.
• Electronic and electromagnetic
sensors,
• Electrical switches
Industrial computers are used to
replace the manual control of a
pneumatic system.
 Signal flow in electro-
pneumatic control system
 Signal flow
1. Signal input: usually generated from a sensor or
a switch.
2. Signal processing: It is processed in the
processing station such as OR gate, AND gate or
time delay valve.
3. Signal output: the signal forms as a link between
the signal control section and the power section
4. Command execution: it takes place at high
power level either for:
– High speed-fast ejection of product.
– Apply high force as in power presses.
 Advantages of electro-pneumatic
systems

1. Greater reliability (Less moving parts subjected to

wear).
2. Reduced installation complexity (Less
components and hoses).
3. The control system can be easily modified
and adapted (It is easier to change wiring and modify
programs rather than changing mechanical components
and hose networks).
4. Easy handling (less complexity).
5. Secure mounting (fewer hoses).
6. Environmentally-friendly coupling system
(Less lubrication require).
 Components of electro-
pneumatic system

1. DC power supply.
2. Switches.
3. Relays.
4. Solenoid valves.
5. Sensor.
 The DC power supply
• It is used to reduce and convert the
230 V AC to a 24 V DC
• It’s components are:
– Transformer
– Rectifier
– Stabilizer
The DC power supply
 Criteria for selecting power supplies

• The magnitude of voltage and current it

can supply.
• How stable its output voltage or current is
under varying load conditions.
• Whether it provides continuous or
pulsed energy.
 Switches
• They are installed in an electric circuit to
connect or interrupt the electric current.
• They are divided into:
1- Control switches: keep the selected position such
as detent switches.
2. Push button switches: maintain the selected
position as long as the switch is activated.
Types of switches to be discussed
• Push button switches.
• Detent switches.
• Limit switches
 Push button switches
• They are activated manually
and used connect or
disconnect the electric current
in he control circuit.
• There are three typed of the
push button switches:
–Normally open contact (make)
–Normally close contact (break)
–Changeover contact (two way)
 Normally open contact (make)
• In this case the circuit is open if the switch is in
its initial position
• Pressing the pushbutton results in closing the
circuit and then the current will flow to load.
• When the plunger is released the spring will
returns the switch to it initial position.
 Normally close contact (break)
• In this case the circuit is closed when the
switch is in its initial position.
• The circuit is interrupted by pressing the
pushbutton..
 Changeover contact (two way)
• It combines the function of the normally open
and normally closed.
• They are used to close one circuit and open
another circuit in one switching operation.
• In the (ATHS) labs, these types of switches are
combined in one switch block
 Detent switches
• These switches keep the selected position; the
switch position remains unchanged until a
new switch position is selected.
• It is called detent switch or a latching switch.
• They are designed to be as normally open,
normally closed or changeover switches.

Symbol of N/O Symbol of N/C

Detent Switch detent Switch
Limit switches
 Limit switches
• The limit switch is actuated when a machine part
or a work-piece is in a certain position. Normally,
actuation is affected by a cam or cylinder piston.
• They are normally changeover contacts.
• The limit switch can be used in circuits according
to one of the following:
– Normally open switch
– Normally closed switch
– Changeover switch
 Relays
• A relay is defined as an electromagnetically
actuated switch.
• When the voltage is applied to a solenoid coil
terminals (A1, A2) will become an electromagnet
which in turn attracts the contacts of the relay
either closing or opening them.
 Relays
• The spring returns the contacts to the initial
position immediately after disconnecting the
voltage at the coil terminals.
 Some advantages of a relay
• It can be used to switch one or more contacts.
• To switch a high current circuit with a low
current circuit

Symbol
Relay Relay block
 Safety and operation
1. Pressurized air lines that become detached
can cause accidents. Switch off pressure
immediately.
2. First connect all tubing and secure before
switching on the compressed air.
3. Cylinders may advance or retract as soon as
the compressed air is switched on.
4. Do not operate the electrical limit switch
manually during fault finding (use a tools only).
 Safety and operation
5. Limit switches should be fixed in such a way
that they contact the trip cam of the cylinder
only in the determined direction.
6. Do not exceed the permissible working
pressure.
7. Use only low voltages of ≤ 24 V.
8. Switch off the air and voltage supply before
disconnecting the circuit.
 Practical Task 1
• Controlling an electric bulb lighting using
different types of switches.
• Background:
The student should know how to use the
Pushbutton, detent and changeover switches
that will be used to switch on/off a lamp using
different circuit configurations.
 Practical Task 1
• Required components:
1- DC power supply (Fig. a)
2- Indicator unit (Fig. b)
3- Switch block (Fig. c)
4- Limit switch (Fig. d)

(a) (b) (c) (d)

 Practical Task 1
•Procedures:
Use a Push Button and a Detent Switch.

Push Button
Detent SW
SW

N.O NC
 Practical Task 1
•Procedures:
Use a limit Switch as a change over switch
 Indirect control of a lamp using a
pushbutton switch and a relay.
• Background:
• The relay is an electromagnetically operated switch;
it will be used to indirectly control a 24V lamp
through a pushbutton switch.
• Required Components:
1- DC power supply
2- Indicator unit
3- Switch block
4- Relay block
 Indirect control of a lamp using a
pushbutton switch and a relay.
• Connect with a Push Button and a relay (N/O) and
(N/C) and press the push button. AND OBSERVE

(N/O) Relay (N/C) Relay

 Indirect control of a lamp using a
Detent switch and a relay.
• Connect with a Detent Sw. and a relay (N/O) and (N/C)
and press the Detent Sw. AND OBSERVE
 Practical Task 3
Opening/closing the flow in a pipeline
• The double acting cylinder (1A) in the Figure is
used to open and close the main valve in a
pipeline. Draw an electro-pneumatic circuit to
control the movement of cylinder (1A).
 Solution-1 to Practical Task 3 with
a double acting cylinder
• Required components
with a double acting
cylinder:
– Double – acting
cylinder
– 5/2 way valve,
double solenoid
– Power supply
– Switches
Solution-2 to Practical Task 3
with a double acting cylinder
Solution to Practical Task 3