HYDRAULICS & PNEUMATICS

Introduction to
Electro-pneumatics

Lecture 7
: Dr. M Namoshe
1
Introduction to electro-pneumatics

2
different applications of electro-pneumatic machines

Milk filling machine

3
different applications of electro-pneumatic machines

Yogurt filling machine

4
Signals
 Signals :  • A Signal is the representation of information by means of the value or value pattern of physical variable.

• Analog Signal :

- Information is assigned point by point to a continuous value range of the signal parameter.
- Example : pressure gauge–each pressure value (information parameter) is assigned a particular
display value (information).

• Digital Signal :

- A digital signal is a signal with a finite number of value ranges of the information parameter. Each
value range is assigned a specific item of information.
- Example: A pressure measuring system with a digital display shows the pressure in increments of 1
bar. There are 8 possible display values (0 to 7 bar) for a pressure range of 7 bar.

• Binary Signal :

- A binary signal is a digital signal with only two value ranges for the information parameter. These
are normally designated 0 and 1. A control lamp indicates whether a pneumatic system is being
correctly supplied with compressed air.
-> If the supply pressure (= signal) is below 5 bar, the control lamp is off (0 status).
-> If the pressure is above 5 bar, the control lamp is on (1 status).

5
Controllers
 Controllers can be divided into different categories
according to the type of information representation,
into analogue, digital and binary controllers.

6
Introduction to electro-pneumatics

 In electro-pneumatics, the pneumatic components are controlled by

using electrical and electronic circuits. Electronic and electromagnetic

sensors, electrical switches and industrial computers are used to

replace the manual control of a pneumatic system.

7
Signal Flow in a Control
System
A controller can be divided into the functions: signal input, signal processing, signal output
and command execution. The components in the circuit diagram of a purely pneumatic
controller are arranged so that the signal flow is clear. Bottom up : Input elements(such as
manually operated valves), Logical association elements(such as two-pressure valves),
Signal output elements(power valves, such as 5/2-way valves), Command execution(such as
cylinders).

- Input elements(such as manually operated valves)

- Logical association elements(such as two-pressure valves)
- Signal output elements(power valves, such as 5/2-way valves)
- Command execution(such as cylinders).
8
 Pneumatic vs Eletropneumatic
Systems 
 Both pneumatic and electro-pneumatic controllers have a pneumatic
power section. The signal control section varies according to type.

• In a pneumatic control pneumatic components are used, that is,

various types of valves, sequencers, air barriers, etc.

• In an electro-pneumatic control the signal control section is made

up of a electrical components, for example with electrical input
buttons, proximity switches, relays, or a programmable logic
controller.

• The directional control valves form the interface between the signal
control section and the pneumatic power section in both types of
controller.
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Pneumatic control system 

12
Electro-Pneumatic control system

13
 Operation of Electro-pneumatic
Controller
 In contrast to a purely pneumatic control system, electro-pneumatic
controllers are not shown in any single overall circuit diagram, but in two
separate circuit diagrams - one for the electrical part and one for the
pneumatic part.

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Advantages of electro-pneumatic systems:

1- Greater reliability:

Less moving parts subjected to wear compared to mechanical control

systems.

2- Reduced installation complexity:

Less components and hoses, leads to less effort in planning and

commissioning especially with large and complex systems.

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Advantages of electro-pneumatic systems:

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.

 Example: the AND gate is replaced with logic and through using

electrical switches.

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Advantages of electro-pneumatic systems:

4- Easy handling: Less complexity

5- Secure mounting: Fewer hoses

6- Environmentally-friendly coupling system: Less lubrication require

17
Components of electro-pneumatic system

 The electro pneumatic system is normally consists of the following

items:

1. DC power supply

2. Switches

3. Relays

4. Solenoid valves

5. Sensors
18
DC power supply

 The power supply is used to reduce and convert the 230 V AC to a

24 V DC.

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DC power supply
 The power supply components which are shown below have the following

functions:

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The transformer
 The transformer reduces the main voltage (230 to 24 volt).

21
The rectifier
 The rectifier converts the AC voltage to DC voltage.

22
The stabilizer
 The stabilizer is used to smooth and maintain constant voltage at the

output.

23
 Switches
 Switches are installed in an electric circuit to connect or interrupt

the electric current.

 These switches 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.

24
 Switches
 In this module, three types of switches will be discussed:

Push button Detent

switches switches

Limit
switches

25
Push button switches
 These switches are activated manually and used to connect or

disconnect the electric current in the control circuit. There are three

types of the push button switches:

Normally Normally closed Changeover

opened contact contact contact
(make) (break) (two-way)

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Normally opened contact (make)
 In the case of a normally opened switch, 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 its initial position.

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Normally closed contact (break)
 In the case of the normally closed switch, the circuit is closed when the

switch is in its initial position. The circuit is interrupted by pressing the

pushbutton. The figure shows the ISO symbol of the push button N/C.

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Changeover contact (two-way)

The changeover contact, shown below combines the function of the

normally open and normally closed. Changeover contacts are used to

close one circuit and open another circuit in one switching operation.

2 4

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Push button switches
 In many labs, these types of switches are combined in one switch

block as illustrated in the figure:

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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.

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Detent switches

 The figures below show the ISO symbol of the normally open detent

switch and normally closed detent switch respectively.

 Detent switches also designed to be as normally open, normally

closed or changeover switches.

32
Detent switches
 In many labs, the detent switches are included in the same switch

block with pushbutton switches, as shown in the figure below:

33
Limit switches
 The limit switch (shown below) 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.

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Limit switches
 Limit switches are normally changeover contacts and can be

connected according to the required control circuit. The limit switch can

be used in circuit according to one of the following:

 Normally open switch

 Normally closed switch

 Changeover switch

35
Relays
• A relay is an electromagnetically actuated switch.

• When a voltage is applied to the solenoid coil, an

electromagnet field results. This causes the armature to
be attracted to the coil core.

• The armature actuates the relay contacts, either closing

or opening them, depending on the design.

• A return spring returns the armature to its initial

position when the current to the coil is interrupted.
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Single contact Relay

37
Relay…
A relay coil can switch one or more contacts. In
addition to the type of relay described above, there
are other types of electromagnetically actuated
switch, such as the retentive relay, the time relay, and
the contactor.

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Construction of the Relay

39
Types of relay
 Retentive Relay :

• The retentive relay responds to current pulses :

- The armature is energised when a positive pulse is applied.
- The armature is de-energised when a negative pulse is applied.
- If no input signal is applied, the previously set switch position is retained (retention).

• The behavior of a retentive relay is analogous to that of a pneumatic double pilot valve, which
responds to pressure pulses.

Time Relay :
• There are two types of time relay :–

- Pull-in delay and 

- Drop-out delay.

• With pull-in delay, the armature is energized after a set delay; drop-out however, is effected
without delay.
• The reverse applies in the case of the drop-out delay relay.

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Pull-in delay time relay

41
Drop-out delay time relay

42
Relays
 An ISO symbol of the relay and a lab relay block is also illustrated in the

below figure:

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Advantages of Relays
 Some advantages of a relay:

1.It can be used to switch one or more contacts.

2.To switch a high current circuit with a low current circuit.

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Contacts
 • A contactor has multiple switching elements, normally four to ten contacts.

• For contactors – as for relays – there are various types with combinations of 

- Normally open contact.

- Normally closed contact.
- Changeover contact.
- Delayed normally closed contact etc.

• Contactors that only switch auxiliary contacts (control contacts) are called
contactor relays.

• Contactors with main and auxiliary contacts are called main or power
contactors.

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Contacts construction design

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Safety and operation
 The following points should be observed while working with electro-

pneumatic systems:

1. Pressurized air lines that become

detached can cause accidents.

Switch off pressure immediately.

47
Safety and operation

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 tool only). 48

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.
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50
Introduction
 Two forms of energies are used to operate any electro-pneumatic

control system:

 Electrical energy

 Compressed air energy

51
Introduction
 Electrically actuated directional control valves (DCVs) are switched with

the aid of an electric coil that is called a solenoid. The electric coil attracts

or repels the valve spool as shown below:

52
Introduction
 When the pushbutton switch is pressed (activated), an electric

current flows through the solenoid coil, the solenoid is energized

causing the valve spool to move, which in turn will switch the valve to

the second position where the air flows to move the cylinder piston

forward as illustrated in the following figure:

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54
Introduction
 Releasing the pushbutton terminates the current flow, which in turn

de-energizes the solenoid and the DCV moves back to its normal

position.

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Types of solenoid valves

 There are two types of solenoid valves used in electro-pneumatic

systems:

Single solenoid valve

with a spring return Double solenoid valves.
(reset)

56
Single solenoid valve with a spring return (reset)

 The valve remains in the actuated position as long as the current

flows through the solenoid.

57
Single solenoid valve with a spring return (reset)

 Example: 5/2 DCV with single solenoid and spring return:

58
Double solenoid valves
 The valve will keep and maintain the last switched position even

when no current flows through the solenoid. It is sometimes called

memory valve.

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Double solenoid valves
 Example: 5/2 DCV, with double solenoid:

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61
Control in electro-pneumatics

 There are two general ways to control the electro-pneumatic systems:

Direct Control Indirect

Control

62
Direct control in electro-pneumatics

 Direct control is the control of an

electro-pneumatic valve without using

intermediate components such as a relay,

a contactor or an industrial computer

(PLC). The valve is connected directly to

electric switch as shown in the figure:

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Advantages of direct control

 Simple and easy

 Less wiring

 Cheap

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Disadvantages of direct control

 Remote control is not possible

 Switching more than one valve at a time is not possible

 Latching is not possible

 Design improvement is not flexible

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Indirect control in electro pneumatics
 Indirect control is the control of an electro-pneumatic valve using

intermediate components such as relays, contactors or programmable

logic controllers (PLC).

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Advantages of indirect control systems

 Remote control is possible

 Switching more than one valve at a time is possible

 Latching is possible

 Flexible design improvement and development

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Disadvantages of Indirect control

 Complicated

 More wiring

 More cost involved

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 The end.

Motsemme tshephang 69