Pneumatic Systems

Basics, Components, Circuits and

Cascade Design

”Class code “b4lfic5

 Basic of Pneumatics (Air)
The earth is surrounded by an
envelope of air known as atmosphere.
The composition of this 12 mile thick
envelope is shown in the figure. Due to
the compressibility of air, increasing
the pressure causes decrease in the
volume of air.
The Perfect Gas Laws

Boyle/Marriot’s law
Boyle discovered that the pressure and the volume of a
particular quantity of gas was constant provided that the
temperature did not vary.
PV = C
P1 V1 = P2 V2

Charles’s law
Charles found that the volume of a gas increased in equal
amounts for equal increase increments of Temperature, if
pressure is constant.
Lussac’s law
This law indicates that if the volume of a given gas is held
constant, the pressure exerted by the gas is directly
proportional to its absolute temperature.

General Gas law

Combination of the mentioned laws results is general law as
The usefulness of using compresses air as a power source is as:
1. Cleanness
2. Pressure is transmitted
undiminished in all
direction throughout the
system
3. Low cost
4. The best solution for
the jig and fixture
systems, automation lines,
pick and place in
electronics industry.
However, a typical maximum pressure for the pneumatic
systems is 7 to 10 bars. This indicates that the pneumatic
systems aren't suitable for the heavy duty in terms of load.
Pneumatics Components
Compressors

A compressor is a machine that compresses air or another

type of gas from a low inlet pressure (usually atmospheric) to
a higher desired pressure level. This is accomplished by
reducing the volume of the gas. Air compressors are generally
positive displacement units and are either of the reciprocating
piston type or the rotary screw or rotary vane types.
Piston compressor

In this type of compressor a cylinder bore encloses a moving

piston. As the crankshaft of the compressor rotate, the piston
moves within the cylinder, similar to the piston in a car
engine. As the piston is pulled down, the volume increases,
creating a lower atmospheric pressure in the piston chamber.
This difference in pressure causes air to enter via the inlet
valve. As the piston is forced upwards the volume of air
reduces.
The air pressure therefore increases. Eventually the
pressure forces the outlet valve to open.
To avoid an excessive rise in temperature. Multi-stage
compressors with INTERCOOLERS have been developed.
These compressors can generate higher pressures than
single stage compressors. The most common type is the
Two-Stage compressor. The following figures show how this
compressor works.
 Vane compressor

The following figure shows

a cutaway view of the
sliding-vane-type rotary
compressor. The air inlet is
placed where the volume of
the compression chamber
is greatest, the outlet where
the volume is smallest.
Consequently, as the vanes
turn, the space between
them is reduced. This
reduction in volume
compresses the air as it
travels from the inlet to the
outlet.
Screw compressor
There is a current toward
increased use of the rotary-
type compressor due to
technological advances,
which have produced stronger
materials and better
manufacturing process. The
following figure shows a
cutaway view of a single-
stage screw type compressor.
Precise positioning of the screw is essential for its
performance. Oil provides a seal between the rotating screws
as well as lubricating the parts and cooling the air. The oil is
then separated from the air before it enters the system.
 Lobe compressor

In this type of
compressor the rotors do
not touch and certain
amount of slip exists.
This slip increases as the
output pressure
increases. It is therefore
operated at maximum
speed for the highest
efficiency. 17.3 bar is
obtainable with this type
of constant displacement
compressor.
Air Conditioners
Air Filters

The air needs to be filtered to be free of moisture and

contamination. Air filter is used to do this job. The filter
elements remove the particles and moisture as small as 5
microns.

Symbols
Air pressure regulator

The pressure regulator is used to adjust

the desired pressure for the pneumatic
system. This use a piston to sense
downstream pressure fluctuations. The
piston, in turn, works against a set Symbols

spring pressure. As the pressure

downstream drops it is sensed by the
diaphragm and the popper valve opens.
This adjusts the position of the poppet
valve, which limits the downstream
pressure to the pre-set valve.
Air lubricator

A lubricator ensures proper lubrication of internal moving parts

pneumatics components. The proportional increase in oil mist
by an increase of air flow is achieved by the spring loaded
poppet assembly. As the flow increases and the valve opens,
the area is increased and a pressure differential created.

Symbols
Air service unit

Filters, regulators and lubricators can be combined to ensure

optimum compressed air preparation for a specific pneumatic
system.

Symbols
Pneumatic Silencer

To decrease the noise of air in the outlet of valves, a silencer

can be used. They are made from the porous plastic or
bronze. Some of them are equipped with a control flow valve
to control velocity of flow in the outlet of valves as well.

Symbols
Pneumatic Actuators
Pneumatic Cylinders

The cylinders converts the energy of the compressed air

into linear motion which extend or retract the piston rod.

Symbols
Pneumatic Rotary Actuators

The rotary actuators converts the energy into a rotary motion.

Most of them is Vane air motor.

Symbols
Pneumatic Semi-Rotary Actuators

Limited rotary motion can be achieved by incorporating a

rack and pinion into a linear actuator or as seen opposite by
a Vane Mechanism within the body of the cylinder.

Symbols
Pneumatic Valves

The pneumatic valves are similar to hydraulic valves in terms

of physical concepts. They are categorized into three classes:
The same symbols as Hydraulic components are used for
the pneumatic components.
However, it is necessary to use an unfilled arrow marker.
In the following, we only study the pneumatic directional
control valves.
Directional Control Valves (n-way sliding spool valve)

This control is provided by various valves in pneumatic

systems. For example the following figure shoes a cutaway
of a 5/2 valves.
2/2 Pneumatic Valve

3/2 Pneumatic Valve

4/2 Pneumatic Valve

5/2 Pneumatic Valve

 5/3 Pneumatic Valve

Actuating systems

In the pneumatic valves, the same mechanism are used to

activate the DCV’s. The most common actuating system
are Solenoid and Manual control.
Pneumatics Circuits and Applications
Pneumatic circuit design consideration

When analyzing or designing a pneumatic circuits, the

following four important considerations must be taken into
account:
• Safety of operation
• Performance of desired functions
• Efficiency of operation
• Costs
The typical cost for the compressing air to 100 psig is about
$0.35 per 1000 ft3 of standard air.
 Basics Pneumatic circuits
A pneumatic circuit is usually designed to implement the desired
logics. However, there are several basics circuits, which can be
integrated into the final circuit.
Air pilot control of double-acting cylinder
Purpose: To operate a
double-acting cylinder
remotely through the use of
an air pilot-actuated DCV.
How: Using a low pressure
(10 psi) for supplying two
push-button valves and
activating them manually
causes the main DCV to
activate for cylinder
retraction or extension.
Cylinder Cycle Timing System

How: When push-button valve V3 is

momentarily actuated, valve V2
shifts to extend the cylinder. When
Purpose: To provide a the piston rod cam actuates limit
timed cylinder extend valve V4, it shifts V2 into its opposite
and retract cycle. mode to retract the cylinder. Flow
control valve V1 controls the flow-rate
and thus cylinder speed.
The logic OR function

The pneumatic logic OR function can be achieved using a shuttle valve

2 2
2

1 1
1 1 1 1
The logic AND function

The pneumatic logic AND function can be achieved using a two-pressure

valve 2 2
2 2

1 1 1 1 1 1 1 1
2 2
ISO 1219-1 Popular old
symbol symbol
1 1 1 1
Two-step Speed Control System
Purpose: To provide a timed cylinder extend and retract cycle.

How: Assuming that

flow control valve
V3 is adjusted to
allow a greater flow-
rate than valve V4.
Initially the cylinder
is fully retracted.

When push-button valve V1 is actuated, air goes through valves

V2 and V3 and the shuttle valve V5 to extend the cylinder a high
speed. When the piston rod cam actuates valve V6, valve V2
shifts. The flow is therefore diverted to valve V4 and through the
shuttle valve.
The latch(memory) circuit

In this arrangement an output device will remain actuated until

the original fluid power signal is 'cancelled' and a further signal
is provided to actuate the output device in a different mode.

Upon operation of push-button A, a signal is generated at the

2(A) port and the pilot port 14(Z) of valve C. The 5/2-way
memory valve switches and the signal from port 4(A) fully
extends the cylinder F. If the push-button valve A is released, the
signal at 14(Z) is exhausted at the 3(R) port of the push-button
valve A.
The valve C remains in the switched position until the push-button
valve B is operated. If the push-button valve A is released and
therefore there is no signal at 14(Z) then the signal generated by B
will return the memory valve to its initial position and the cylinder
retracts. The cylinder remains retracted until a new signal is
generated at 14(Z) by the valve A. The cylinder piston rod will
extend and retract if there are no obstructions, but there is no
confirmation that the cylinder is in its fully extended position. If
both the 14(Z) signal and the 12(Y) signal are active due to both
push-buttons being operated, then the memory valve will remain
in the last position.
The flow control valves D and E have been fitted to throttle the
exhausting air in both directions of piston motion. The supply air
is transferred through the bypass check valve of the flow control
valves, giving unrestricted supply to the cylinder.
Control of air Motor
Purpose: To control an air
motor
How: When the STRAT
pushbutton valve is
actuated momentarily, the
air pilot valve shifts to
supply air to motor.
When the STOP push-
button valve is actuated
momentarily, the air pilot
valve shifts into its
opposite mode to shut off
the supply of air to the
motor.
 Deceleration Air Cushion of Cylinder
Purpose: To provide an adjustable
deceleration air cushion at both
ends of the stroke of a cylinder
when it drives a load of large
weight.
How: Valve V1 supplies air to the
rod end of the cylinder and to the
pilot of valve V5 through flow control
valve V3. Free air exhausting from
the blank end of the cylinder permits
a fast cylinder-retraction stroke until
valve V5 operates due to exhaust is
restricted by valve V7. The resulting
pressure buildup in the blank end of
the cylinder acts as an air cushion
to gradually slow down the large
weight load.
Example : In a press shop, stamping operation to be performed
using a stamping machine. Before stamping, work piece has to
be clamped under stamping station. Then stamping tool comes
and performs stamping operation. Work piece must be
unclamped only after stamping operation.

Step 1: Write the statement of the problem:

Let A be the clamping cylinder and B be the stamping cylinder as
shown in the Figure. First cylinder A extends and brings under
stamping station where cylinder B is located. Cylinder B then
extends and stamps the job. Cylinder A can return back only
cylinder B has retracted fully.
Step 2: Draw the positional layout.
Step3: Represent the control task using notational form
Cylinder A advancing step is designated as A+
Cylinder A retracting step is designated as A-
Cylinder B advancing step is designated as B+
Cylinder B retracting step is designated as B-
Therefore, given sequence for clamping and stamping is A+B+B-A-

Step 4 Draw the

Displacement –
step diagram
Step 5 Draw the Displacement –time diagram
Step 6: Analyze and Draw Pneumatic circuit.

Step 6.1 Analyze input and output signals.

Input Signals
Cylinder A - Limit switch at home position a0
Limit switch at home position a1
Cylinder B - Limit switch at home position b0
Limit switch at home position b1

Output Signal
Forward motion of cylinder A ( A+)
Return motion of cylinder A (A-)
Forward motion of cylinder B( B+)
Return motion of cylinder B( B-)
Step 6.2 Using the displacement time/step diagram link input signal
and output signal.
Usually start signal is also required along with a0 signal for obtaining A+
motion.
1. A+ action generates sensor signal a1, which is used for B+ motion
2. B+ action generates sensor signal b1, which is used for B- motion
3. B- action generates sensor signal b0, which is used for A- motion
4. A- action generates sensor signal a0, which is used for A+ motion
Above information (given in 6.2) is shown below graphically
Step 7 Draw the power circuit
i) Draw the cylinders A(1.0) and B(2.0).
ii) Draw the DCVs 1.1 and 2.1 in unactuated conditions
iii) Mark the limit switch positions for cylinders A(1.0) and B(2.0).
Step 8 Draw the control circuit
Step 9 Analysis of pneumatic circuit
1.When the start button is pressed, the signal appears at port 14 of valve
1.1 through limit switch signal a0.
2. Check for the presence of the signal at the other end (12) of valve 1.1.
Notice that the signal is also present at port 12 of valve 1.1. (because b0
is also pressed). This results in signal conflict and valve 1.1 is unable to
move.
3. Let us assume for time being, b0 is somehow disengaged so that valve 1.1
can switch over and consequently cylinder A can extend. When the start button
is pressed.
4. When cylinder A fully extends, it generates a limit switch signal a1,
which is applied to port 14 of the valve 2.1.
5. Check for the presence of the signal at the other end (12) of valve
2.1. Signal is not present at port 12 of valve 2.1 and hence there is no
signal conflict
6. Signal applied to port 14 of the valve 2.1 causes the shifting of DCV
2.1 and cylinder B extends.
7. When cylinder B fully extends, it generates a limit switch signal b1,
which is applied to port 12 of valve 2.1
8. Check for the presence of the signal at the other end of 14 of valve
2.1. It can be seen that signal is also present at the port 14 of valve
2.1(because a1 is also pressed).
This results in signal conflict and valve 2.1 is unable to move
9. Let us assume for time being, b1 is somehow disengaged so that valve
2.1 can switch over and consequently cylinder B can retract.
10. When the cylinder B is fully retracted, it generates a limit switch signal
b0, which is applied to port 12 of the valve 1.1.
11. Check for the signal at the other end 14 of the valve 1.1 Notice that
signal is not present at port 14 of the valve 1.1 and hence there is no signal
conflict. So valve 1.1 can switch over and Cylinder A can retract.

CASCADE METHOD
A Bi-stable memory valve or reversing valve can be used to eliminate
signal conflicts. Signal conflict is avoided by allowing the signal to be
effective only at times when they are needed. Two of the possible designs
are possible.
i) Cascade method
ii) Shift register method
Cascade Pneumatic Circuit Design
Implementation of a sequence of actions by a full pneumatic
circuit is widely used in industries. Many industries like
automotive, food, chemical and so on need to use a full
pneumatic system due to the hazardous area in the site and
limitation of use of the electricity in the system.
Procedure
1. Code the cylinders with letters. Use positive and negative
signs to show the cylinders’ positions: positive sign to
indicate the cylinder is completely extended, and negative
sign to indicate the cylinder is completely retracted:
A+B+B-C+A-C-
2. Split the motion sequence into groups in a way that any
letter regardless of its sign appears only once in each
group: A+B+ / B-C+A- / C-
3. Number the groups: I II III
4. For each cylinder, consider two limit valves to signal the
start and end of its motion and one 4/2 or 5/2 power valve to
operate the cylinder.
5. For the number of groups minus one consider 4/2
directional control valves and connect them in series or
cascade as:
a) Connect the pilot line and air port of the first power and
limit valve of each group to its associated control line (I, II,
III).
b) Follow the sequence of each group and connect the limit
valves to appropriate pilot lines of the power valves.
c) Connect the output of the last limit valve of each group to
the pilot line of the group selector valve.
d) Add any extra valves for safety, emergency and resetting
purposes.
Demonstration of Cascade method
In order to develop control circuitry for multi cylinder applications, as done
before in classic method, it is necessary to draw the motion diagram to
understand the sequence of actuation of various signal input switches-limit
switches and sensors. Motion diagram represents status of cylinder position
-whether extended or retracted in a particular step

Step 1: Write the statement of the problem:

First cylinder A extends and brings under stamping station where cylinder
B is located. Cylinder B then extends and stamps the job. Cylinder A can
return back only cylinder B has retracted fully.
Step 2: Draw the positional layout.
Step3: Represent the control task using notational form
Cylinder A advancing step is designated as A+
Cylinder A retracting step is designated as A-
Cylinder B advancing step is designated as B+
Cylinder B retracting step is designated as B-
Given sequence for clamping and stamping is A+B+B-A-

Step 4
Draw the
Displacem
ent –step
diagram
Step 5 Draw the Displacement –time diagram
Step 6: Analyses and Draw Pneumatic circuit.
Step 6.1 Analyses input and output signals.
Input Signals
Cylinder A – Limit switch at home position a0
Limit switch at home position a1
Cylinder B - Limit switch at home position b0
Limit switch at home position b1
Output Signal
Forward motion of cylinder A ( A+)
Return motion of cylinder A (A-)
Forward motion of cylinder B ( B+)
Return motion of cylinder B( B+)
Step 6.2 Using the displacement time/step diagram link input signal and
output signal.
Usually start signal is also required along with a0 signal for obtaining A+
motion.
1. A+ action generates sensor signal a1, which is used for B+ motion
2. B+ action generates sensor signal b1, which is used group changing.
3. B- action generates sensor signal b0, which is used for A- motion
4. A- action generates sensor signal a0, which is used for group changing
Above information (given in 6.2) is shown below graphically
Step 7 Draw the power circuit
i) Divide the given circuits into groups. Grouping should be done such that
there is no signal conflict. Do not put A+ and A- in the same group.
Similarly B+ and B- should not be put in the same group. In other word
A+ and A- should belong to different group to avoid signal conflict.

In our example of A+ B+ B- A- we can group as

ii) Choose the number of group changing valve = no of groups -1
In this example, it has 2 groups so, needs one group changing valve
Connect the group changing valve as follows. From the figure it is clear
that when the control signals I and II are applied to group changing valve,
the air (power) supply changes from Group 1(G1) to Group 2 (G2)
 iii) Arrange the limit switch and start button as given below

iv) Draw the power circuit

Step 8 Draw the
control circuit
Step 9 Analysis of pneumatic circuit
1. Assume that air is available in the line G2 to start with. (Say from last
operation)
2. When the start button is pressed, Air supply from Group G2 is
directed to line 2 through actuated limit switch a0. Now the air available
in line 2, actuates the Group changing valve (GCV) to switch over to
position I. This switching of the GCV causes air supply to change from
G2 to G1.
3. Now the air is available in line G1. The air supply from group G1 is
directed to port 14 of the valve 1.1. As there is no possibility of signal
conflict here, valve 1.1 switches over causing the A+ action.
.
4. limit switch a1 is actuated as the result of A+ action, allowing the air
supply from the Group G1 to reach to line 1 through a1. Now the air
available reaches port 14 of valve 2.1. As there is no possibility of
signal conflict here, valve 2.1 switches over, causing B+ action
automatically.
5. limit switch b1 is actuated as result of B+ action, allowing the air
supply in line 3. Air from line 3 allows the air to reach port 12 of Group
changing valve (also called reversing valve). As a result, the Group
changing valve switches over, causing the group supply to change from
G1 to G2.
6. Now the air is available in G2. Air from G2 acts on port 12 of the
Valve 2.1. As there is no possibility of signal conflict here, valve 2.1
switches over, causing B- action automatically.
7. limit switch is actuated as the result of B- action. Now the air is
available in line 4.Air from line 4 reach port 12 of the valve 1.1 , As there
is no possibility of signal conflict here, valve 2.1 switches over , causing
A- action automatically.
The cascade system provides a straightforward method of designing any
sequential circuit. Following are the important points to note:
a) Present – the system must be set to the last group for start-up
b) Pressure drop- Because the air supply is cascaded, a large circuit can
suffer from more pressure drop.
c) Cost – Costly due to additional reversing valves and other hardware.
 ‫أ‪.‬م‪.‬د‪ .‬ماهر يحيى سـلوم‬
‫دكتوراه هندسة ميكانيكية‬
‫قسم هندسة الميكاترونكس‬
‫كليه الهندسة الخوارزمي‬
‫جامعة بغداد‬

‫”‪Class code “b4lfic5‬‬

‫‪07901309789‬‬
‫‪drmahir@kecbu.uobaghdad.edu.iq‬‬