Module-4

PNEUMATIC POWER SYSTEM

Syllabus
• Introduction to Pneumatic Control: Definition of pneumatic system, advantages,
• limitations, applications, Choice of working medium. Characteristic of compressed air.
• Structure of Pneumatic control System,fluid conditioners and FRL unit. Pneumatic
• Actuators: Linear cylinder - Types, Conventional type of cylinder- working, End
• position cushioning, seals, mounting arrangements- Applications. Rod - Less cylinders
• types, working, advantages, Rotary cylinders- types construction and application,
• symbols.
• Pneumatic Control Valves: DCV such as poppet, spool, suspended seat type slide
• valve, pressure control valves, flow control valves, types and construction, use of
• memory valve, Quick exhaust valve, time delay valve, shuttle valve, twin pressure
• valve, symbols. Simple Pneumatic Control: Direct and indirect actuation pneumatic
• cylinders, speed control of cylinders - supply air throttling and Exhaust air throttling
• and Exhaust air throttling.
 INTRODUCTION TO PNEUMATIC
The word ‘Pneuma’ means breath or air . Pneumatics
is application of compressed air in automation.

In Pneumatic control, compressed air is used as the

working medium, normally at a pressure from 6 bar
to 8 bar.

Using Pneumatic Control, maximum force up to 50

kN can be developed.

Actuation of the controls can be manual, Pneumatic

or Electrical actuation.
STRUCTURE OF PNEUMATIC CONTROL
SYSTEM
ADVANTAGES OF PNEUMATIC SYSTEM
1. High effectiveness

2. High durability and reliability

3. Simple design
4. High adaptability to harsh environment
5. Safety
6. Easy selection of speed and pressure
7. Environmental friendly
8. Economical
 DISADVANTAGES OF PNEUMATIC
SYSTEM
1. Noise

2. Processing required before use

3. Relatively low accuracy

4. Low loading
5. Uneven moving speed
 APPLICATIONS OF PNEUMATIC
SYSTEM
• The application of pneumatic systems is
very extensive. New uses for pneumatics
are constantly being discovered.
• In construction, it is indispensable source
of power for such tools as air drills,
hammers, wrenches, and even air
cushion supported structures, many
vehicles using air suspension , braking
and pneumatic tires.
• In manufacturing, air is used to power high
speed clamping, drilling, grinding, and
assembly using pneumatic wrenches and
riveting machines.
• Plant air is also used to power hoists and
cushion support to transport loads through
the plant.
 Material handling application

• Positioning
• Clamping
• Shifting
• Branching of material flow
• Turning and inverting of parts
• Transfer of materials
• Stacking of component.
• Sorting of parts.
• Stamping and embossing of component.
 General application

• Machine tool
• Chemical plant.
• Coal mines
• Aircraft.
• Vehicle manufacturing.
• Packaging industry.
• Paper mills.
• Oil refineries.
Comparison between Hydraulic System and Pneumatic System
 Choice of working medium

• The choice of medium depends on the application. Some of the

common, extensive rules followed in the selection of a working
medium are listed below.
1. The Pneumatic system is preferred, when the system
requirement is high speed, medium pressure (usually 6 to 10
bar) and less accuracy of position. If the system requirement is
high pressure and high precision, a fluid system with oil is
good.

2. Air is used where quick response of actuator is required.

3. If temperate variation range in the system is
large, then use of air system may run into
condensation problems and oil is preferred.

4. When high positional accuracy and medium

pressure is required then hydro pneumatic system
is preferred.
5. Air is non-explosive, hence it is preferred where fire/electric

hazard are expected. Oil systems are more prone to fire and

electrical hazards and are not recommended in such applications

6. Because air contains oxygen (about 20%) and is not sufficient

alone to provide adequate lubrication of moving parts and seals,

oil is usually introduced into the air stream near the actuator to

provide this lubrication preventing excessive wear and oxidation.

7. Where the power requirement is high like in forging presses,

sheet metal press, it is impossible to use air system. Oil

hydraulics is the only choice.

 Characteristics
Availability Air is available practically everywhere in unlimited quantities.
Transport Air can be easily transported in pipelines, even over large distances.
Storage Compressed air can be stored in a reservoir and removed as
required. In addition, the reservoir can be transportable.
Temperature Compressed air is relatively insensitive to temperature fluctuations.
This ensures reliable operation, even under extreme conditions.
Explosion proof Compressed air oilers no risk of explosion or fire.
Cleanliness Unlubricated exhaust air is clean. Any unlubricated air which
escapes through leaking pipes or components does not cause
contamination.
Components The operating components are of simple construction and therefore
relatively inexpensive.
Speed Compressed air is a very fast working medium. This enables high
working speeds to be attained
Overload safe Pneumatic tools and operating components can be loaded to the
point of stopping and are therefore overload is safe
 FLUID CONDITIONERS

The purpose of the fluid conditioners is to make the

compressed air more acceptable and suitable fluid medium for
the pneumatic system as well as the operating personal.

The following five fluid conditioners are used in pneumatic

systems

1. Air Filters
2. Air Regulators
3. Air Lubricator
Construction of a Air filter.
 Dryer
Refrigerated dryers
 Chemical Dryer
Adsorption Dryer
Absorption dryer
Lubricators
Pressure regulation
Relief valve
Non-relieving pressure regulator
FRL Units
 PNEUMATIC ACTUATORS

• Drive Elements are Actuators – used to perform

the task of exerting the required force at the end of
the stroke or used to create displacement by the
movement of the piston.
 
• Pneumatic Actuators can be classified as
 Single Acting Cylinders
Conventional Cylinder with Spring Loaded Piston
or
Diaphragm type
 Double Acting Cylinders
 TYPES OF PNEUMATICS ACTUATORS

• i) Linear Actuator or Pneumatic cylinders

• ii) Rotary Actuator or Air motors
• iii) Limited angle Actuators

The different classification scheme of the pneumatic

cylinders are given below
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
•  Single rod type double acting cylinder
•  Double rod type 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 CYLINDER

 Single acting cylinder has one working port

 Forward motion of the piston is accomplished to due to
supply of compressed air behind the piston.
 Return motion of piston takes place only due to built in reset
spring placed on the rod side of the cylinder.
 Single acting cylinders are used for applications such as
clamping, feeding, sorting, locking, ejecting, braking etc.,
where force is required to be exerted only in one direction..
 Single acting cylinder are usually available in short stroke
lengths [ maximum length up to 80 mm] due to the natural
length of the spring.
 Single Acting Cylinder exert force only in one direction.
SINGLE ACTING CYLINDER
 DOUBLE ACTING CYLINDERS
 
 

They are available in different constructions such as

 
 Conventional,
 Double ended piston rod type,
 Rod less type
 Tandem type
 Multi-position type and
 Rotary type..
 DOUBLE ACTING CYLINDERS
 

The seven parts of the double acting cylinder are

1. Base cap with port connection
2. Bearing cap with port connection
3. Cylinder barrel 4. Piston 5. Piston rod 6. Scrapper rings 7. Seals
END POSITION CUSHIONING
 PNEUMATIC CYLINDERS
Symbolic Representation of Pneumatic Cylinders -Linear Actuators
 ROTARY ACTUATORS

In order to achieve angular motion, Rotary Actuators are

used. Rotary actuators are mainly available in two designs.

 Vane type Construction: Further these actuators are available

with 1800 rotation or 2700 angle of rotation. These actuators
can be used for low torque requirement up to 10 N-m.
 Rack and Pinion type construction: Can be used for angle or
rotation close to 3600. These actuators can develop torques
up to 100-150 N-m depending on the diameter of the cylinder
 
 VANE TYPE ROTARY ACTUATOR
 

•A rotating vane connected to a shaft divides cylindrical chamber in to two

compartments. Compressed air is alternately admitted and exhausted from the
chambers. The compressed air pressure acting on the vane surface results in a torque.
Hence rotary motion is obtained.

•The magnitude of the torque produced, depends on the surface area of the vane, air
pressure and mean radius of the vane.
 
 ROTARY ACTUATOR OF RACK AND PINION TYPE

This is essentially a double acting cylinder with a rack arrangement provided on the
piston rod and a pinion engages with this rack. Out put rotation of the pinion shaft
can be used for obtaining angular motion from 0-3600. This type of rotary actuators
are used for higher torque requirement up to 150 N-m.
 Air motors
& Seals

1. PISTON MOTORS & Vane motors

2. Static seals:- Its provide a sealing between the

stationary parts and cylinder.

3. Dynamic seals :-These are used provided for

surfaces which are moving.

 Pneumatic Control

1. Direction control valve:

2. Non return valves:

3. Flow control valves:

4. Pressure control valves:

Poppet type DCV
Two way directional control valve
Three way directional valve
Four way valve
Check valve
Shuttle valve
Quick exhaust valve
Time delay valve
TWIN pressure valve (AND GATE)
Memory valve
Flow control valve
Non return type flow control valve