Pneumatics

System

CONTENT :Fundamentals of pneumatics What is pneumatic system Basic pneumatic system Components of pneumatic system Advantages and Disadvantages of pneumatic system Application of pneumatic system

Fundamentals of pneumatics
Pneumatics is a branch of technology that deals with the study and application of pressurized gas to obtain mechanical motion.

Pneumatic systems are very common, and have much in common with hydraulic systems with a few key differences. Compressed air is normally used to obtain pneumatic energy in industries. However, other inert gases at high pressures are also used. Pneumatics has widespread application in the construction and mining industries.

The reservoir is eliminated as there is no need to collect and store the air between uses in the system. Also because air is a gas , it is compressible and regulators are not needed to recirculate flow. But, the compressibility also means that the systems are not as stiff or strong. Pneumatic systems respond very quickly, and are commonly used for low force applications in many locations on the factory floor.

What is pneumatics system ?

What is Pneumatic systems ?

It is a power transmission system that uses the force of flowing gases to transmit power.
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A pneumatic system is any system that uses air pressure to move either a turbine or a cylinder to accomplish some work. Most pneumatic circuits run at low power -- usually around 2 to 3 horsepower. Because air systems operate at relatively low pressure, the components can be made of relatively inexpensive material -- often by mass production processes such as plastic injection molding, or zinc or aluminum die-casting. This process cuts secondary machining operations and cost.
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First cost of an air circuit may be less than a hydraulic circuit.

Compressing atmospheric air to a nominal working pressure requires a lot of horsepower.

Air motors are one of the most costly components to operate. It takes approximately one horsepower to compress 4 cfm(cubic foot/minute) of atmospheric air to 100 psi. A 1-hp air motor can take up to 60 cfm to operate, so the 1-hp air motor requires (60/4) or 15 compressor horsepower when it runs. Fortunately, an air motor does not have to run continuously but can be cycled as often as needed.
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Basic pneumatic system

Working of pneumatic system

First you need an air compressor that compress air at working pressure, say 100 psi . Air from the air compressor enters a air tank. Which stores the air. Then the air is passed through cleaning section , where filters are placed. Air dryer and mist-separator is used. Air becomes dry when it passes through air dryer. The moisture in the air is very dangerous because it corrode the parts so that it is removed from air by means of mist-separator. The air is then passes through air conditioning section. Where it is cooled. Then it is passes from regulator, where air supply pressure is reduced. Lubricator provide oil in the compressed air . Then the air direction is controlled by direction control valve. This air is used to operate the machine.

Components of pneumatic system

Compressor Check valve Air tank( Reservoir tank ) Filter Regulator Lubricator Solenoid valve Actuator

Compressor
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It compress the air and generates pressure of 120 psi . It cannot be used to generate vacuum. It transfer the compressed air into an air tank or reservoir tank.

Check valve
- Check valves are one-way valves that are installed to the hose connecting the compressor to the reservoir tank. - They allow the compressed air to accumulate in the buffer tanks, but do not allow backflow into the compressor.

Air tank( Reservoir tank )

It can store the air which comes from compressor at 120 psi pressure. These tanks help to prevent uneven airflow surges in the actuators, allow the compressor cycle to maximize its shutoff timing; and allow the compressor to be farther from the actuators in projects where this distance is useful or necessary.

The compressed air in the pneumatic system must be cleaned and conditioned before it can be used by component. This is done by - Filter - Regulator - Lubricator

Filters

A pneumatic filter is a device which removes contaminants from a compressed air stream. Typical commercial pneumatic filters will remove particles as small as 5 micrometers from the air. These contaminants include lubricant particles ejected by the compressor, dirt particles, small water droplets or aerosols, and even oil vapor and dust particles. Secondary filters are used for a variety of applications and can remove particles as small as 50 nanometers in size. These secondary filters can remove fumes, odors, vapor, mist, moisture, oil, and tiny particles from the air stream. In addition the dryer is also used to dry the air. Moisture is removed in this component.

Regulator

A regulator has two functions :- To adjust supply pressure to a desired level. - to maintain a constant air pressure.

It has a knob that can be turned to adjust the air pressure to a lower level. The pressure of the air in the system can be fluctuate.

lubricator

Many pneumatic system components and almost all pneumatic tools require oil lubrication in the air supply line for proper operation and long service life. The permanent lubrication is provided by manufacturer during production. A lubricator can be used to spray a fine mist of oil in the air that is carried downstream to the component.

Solenoid valve

The term solenoid(shown in fig.) usually refers to a coil used to create magnetic fields when wrapped around a magnetic object or core. In engineering terms, the solenoid describes transducer mechanisms used to convert energy into motion. Solenoid valves are controlled by the action of the solenoid and typically control the flow of water or air as a switch. Two solenoid valves * Single solenoid valve:- When energized, cylinder goes to one state. - When de-energized, cylinder always returns to rest state. * Double solenoid valve :-

- One solenoid pulsed to move cylinder one way, other solenoid pulsed to move cylinder the other way.
- Results unpredictable if both pulsed .

Actuator

A pneumatic actuator converts energy (typically in the form of compressed air) into motion. The motion can be rotary or linear, depending on the type of actuator. There are many types of actuators, powered by pressurized air. A Pneumatic actuator mainly consists of a piston, a cylinder, and valves or ports. The pressurized air is released into the cylinder to move a piston forward as the air is forced into the chamber.

Advantages of pneumatic system

Simplicity of Design And Control Machines are easily designed using standard cylinders & other components. Machines operate by simple ON - OFF type control. Reliability Pneumatic systems tend to have long operating lives and require very little maintenance. Because gas is compressible, the equipment is less likely to be damaged by shock. The gas in pneumatics absorbs excessive force, whereas the fluid of hydraulics directly transfers force. Storage Compressed gas can be stored, allowing the use of machines when electrical power is lost. Safety Very low chance of fire (compared to hydraulic oil). Machines can be designed for safe operation in Overloads. The shock absorbent properties of air make overloading safe. Under excessive forces air can compress easily avoiding damage to equipments. Clean & Light in weight Easily transported Variable pressure Less initial cost

Disadvantages of pneumatic system

Preparation - required to remove dirt and humidity. Compressible - not possible to achieve uniform and constant piston speeds. Force required - low working loads - the required output force is economical only upto about 20KN to 30KN. - commonly used working pressure of 7 bar. Cost - The long-term operating cost of these systems can be high because it takes a good deal of power to compress enough gas to allow the system to exert a proper amount of pressure. noisy - Power tools and pneumatic tools are going to make a lot of noise while in use.

Application of pneumatics

Industrial robots ( automation ) Operation of bus doors Operation of machine tools Operation of work holding devices Air tools Medical equipment Packaging machinery Food and beverage industries Metal-cutting and forming machine tools Car washes Plastics machinery Petroleum markets Chemical handling Assembly systems Coolant systems Process industries Pharmaceuticals