BEE1922 Engineering Laboratory II

Pneumatic
By: NAZRIYAH BINTI HAJI CHE ZAN

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1.0 Introduction to Pneumatic

1.1 Pneumatic in review 1.2 Structure & signal flow of pneumatic systems 1.3 Product and preparation of compress air
1.3.1 Compressor 1.3.3 Air Dryer 1.3.5 Service Unit 1.3.2 Reservoir 1.3.4 Piping System

1.4 Safety and Operation

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2.0 Basic pneumatic system component

2.1 Pneumatic Actuator
Linear -Single Acting Cylinder & Double Acting Cylinder Rotary -Pneumatic Motor Directional ctrl valve exercise 1 Non-return Valve - exercise 2 Flow Control Valve exercise 3 Pressure Control valve exercise 4 Combination valve exercise 5 nazriyah@kuktem.edu.my

2.2 Pneumatic Valves

2.0 Basic pneumatic system component

Practical Assessment 1

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3.0 Additional pneumatic system component

3.1 Timer Exercise 6 3.2 Counter 3.3 Sensor
Directional ctrl valve exercise 1 Non-return Valve - exercise 2

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3.0 Additional pneumatic system component

Practical Assessment 2 Final Test

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1.1 Pneumatic in review

Pneumatic Greek word
Pneumos : breath, air Actic : movement, action Pneumatic : control action by air system

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1.1 Pneumatic in review

Advantages
Availability practically everywhere in unlimited quantities Easily transported in pipeline Explosion Proof no risk of explosion or fire Cleanliness Fast Action
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1.1 Pneumatic in review

Disadvantages
Complicated preparation of compressed air-no dirt and condensate allowed! Impossible to get constant piston speed Economical only up to max. 7 bar pressure Exhaust air is loud! (need silencers)

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1.2 Structure & signal flow of pneumatic systems

Signal condition for pneumatic control system
Regulatory control system
3 psig (0%) to 15 psig (100%) Depend on equipment spec.

Sequences system (ON/OFF)

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1.2 Structure & signal flow of pneumatic systems

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Pneumatic and Electrical

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1.3 Product and preparation of compress air

Instrument air system

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1.3.1 Compressor
As an source of air supply to the system. Generate pressurized air to the system. Varies type of compressor such as
Screw compressor Reciprocating piston compressor Radial flow compressor Sliding vane compressor Axial compressor
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1.3.1a Screw Compressor

Air drawn in through suction nozzle move axially via two impeller at high speed. Pressure up to 10 bar Motor drive continues running in idle mode.

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1.3.1b Reciprocating piston Compressor

Draws air in through the suction valve during piston stroked downward. Compress during upward and push out through discharge valve Single stage up to 6 bar Double stage up to 15 bar
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1.3.1c Radial flow Compressor

Through rapidly rotating blades, the air is accelerated radially. Pressure: With multi-stage design up to approx. 1000 kPa (10 bar)

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1.3.1d Sliding vane compressor

Cylinder volume increase with rotor rotation cause air flow into the cylinder Air is sealed within the cylinder vanes & compress by rotation Discharged when compress air pressure reaches outlet pressure. Single stage up to 4bar ; two stage up to 8 bar

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1.3.1e Axial Compressor

Through rapidly rotating blades, the air is accelerated radially. The kinetic energy of the air is converted into pressure energy. Pressure: Up to approx. 600 kPa (6 bar)
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1.3.2 Reservoir
Configure at downstream (after) compressor to stabilize air. To cool an air after compressed by compressor Separated the heavy moisture from air. Some cases pressure control for compressor (compress/idling) are taking from reservoir.
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1.3.3 Air Dryer

Main purpose is to reduce water moisture in the compressed air, call air humidity. Reduce pneumatic device service live if compress air is low humidity or high moisture. To increase humidity to 100, air need to reached dew point.
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1.3.4 Air Filter

Water droplets and solid particles are removed through a filter. Filter fineness
Standard filter: 5 to 40 m Fine filter: 1 m Micro filter: 0.01 m

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1.4 Safety and operation

Do leak test for the system by using
Snooper liquid Soap liquid

Bubble exist at leak position VDI (German Association of Engineer) Design Guidelines for Machine Tool and other Product Equipment:nazriyah@kuktem.edu.my

1.4 Safety and operation

VDI (German Association of Engineer) Design Guidelines for Machine Tool and other Product Equipment: P 4.5.1 Controller malfunction
In the even of controller malfunction or disconnection of the system, operating staff must be not endangered.

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1.4 Safety and operation

P4.5.2 Emergency Stop Switch (ESS)
Pneumatic system using several force cylinder must be equipped with an emergency switch. ESS function is
To put sys into zero pressure status. To reset all force cylinder into initial position To inhibit cylinder in their current position.

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BASIC PNEUMATIC SYSTEM COMPONENT

ACTUATOR VALVE

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2.1 Actuator
An output device to apply control action. Describe to 2 group
Linear motion
Single Acting Cylinder / Actuator Double Acting Cylinder / Actuator Air motor Rotary Cylinder / Actuator
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Rotary motion

Linear-Single Acting Cylinder

Applied air only one side of cylinders piston face or actuator diaphragm. Return back by spring. Force balance concept. Stroke when Fin > Fspring Fin = Psupply X Apiston Fspring = Psupply X Apiston
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Linear-Double Acting Cylinder

Similar to single acting cylinder. Spring function replace by pneumatic supply. This two ports alternately as supply and exhaust ports.
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Rotary - Pneumatic motor

Transform pneumatic energy to mechanical energy. Pneumatic motor

Piston motor Sliding-vane motor Gear motor Turbines

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Cylinder Symbols

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Cylinder Symbols

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2.2 Valve

Function is to control pressure or flow rate of pressure media Divided to below categories:
Directional Control Valve (DCV) Non Return Valve / Checked valve Flow Control Valve Pressure control valve Combination valve
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Directional Control Valve

Switching positions
2 switching port

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Directional Control Valve

Switching positions
2 switching port

Working Port

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Directional Control Valve

Switching positions

2 switching port
3 port

Working Port Flow direction

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Directional Control Valve

Switching positions

2 switching port
3 port

Working Port Flow direction Flow barrier

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Directional Control Valve

Switching positions

2 switching port
3 port

Working Port Flow direction Flow barrier DCV name : Port / working pos. : 3/2 way valve

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Directional Control Valve

2/2 way valve Also call as ON-OFF valve Function is either ON or OFF pneumatic flow.

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Directional Control Valve

3/2 way valve

4/2 way valve

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Directional Control Valve

5/2 way valve

5/3 way valve

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Directional Control Valve

Type of actuator / control signal

Mechanical signal

Return by spring

Pneumatic signal

Indirect Pneumatic, piloted

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Directional Control Valve

Type of actuator / control signal

Electrical signal/ Solenoid Solenoid, piloted, with manual override

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Directional Control Valve

Plunger Valve condition
Pneumatic Flow at Activated condition / Energize (ON) Pneumatic Flow at Normal condition / Not energize (OFF)

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Directional Control Valve

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Example 1 of DCV operation

Push pushbutton, single acting cylinder will extend. Release pushbutton, cylinder will retract back.

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Example 1 of DCV operation

Push pushbutton, single acting cylinder will extend. Release pushbutton, cylinder will retract back.

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Example 2 of DCV operation

Push START pushbutton, double acting cylinder will extend. Push STOP pushbutton, cylinder will retract back.

START

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STOP

Exercise 1
Training aims
Operation of a single acting cylinder Direct actuation of single-acting cylinder Use of 3/2 way DCV Application of a service unit with on-off valve and manifold

Problem description
The allocating device supplies aluminum valve blanks to a machine station. By operated a START push button, the piston rod of the single acting cylinder 1A, is made to advance. By press STOP push button, the piston rod is return.

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Exercise 1-solution

START

STOP

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Non Return Valve

Non Return Valve Shuttle valve (OR Valve) Dual Pressure Valve (AND Valve) Quick Exhaust Valve One way flow control valve**.
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Non Return Valve

a) Non Return Valve
Allowed flow in one direction Input pressure should higher than downstream pressure. Non return valve with spring loaded release a flow when force of input is larger than springs pretension.
a) Non return Valve (check valve)

b) Non return Valve, Spring loaded

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Non Return Valve

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Non Return Valve

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Non Return Valve

b) Shuttle Valve (OR Valve)
Had 2 input and 1 output. Logic OR connection Air present at either 1 or both input will produce an output signal. The output signal is following the higher pressure.
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2 1 1(3)

Non Return Valve

c) Dual-Pressure Valve (AND Valve)
1 2 1(3)

Logic AND connection Output produced when both input is present.

Diff. input, lower pressure reaches the output.

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Non Return Valve

d) Quick Exhaust Valve
Used for quick venting of work elements Become a buster for the actuator.
1 2 3

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Non Return Valve

Example of quick venting valve
Cylinder will expand in normal speed, but high speed (buster) when to retract.

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Exercise 2
Training aims

Indirect actuation of a double acting cylinder Operation of a 5/2 way single pilot valve with spring return Application of a dual-pressure valve Learning a final control element can be influenced via an AND connection
Operating of 2 identical valve by push button cause the forming tool of an edge folding device to thrust downward and fold over the edge of a flat sheet of cross section area 40 X 5. If both or even just one push button is released, double acting cylinder (1A) slowly return to initial position. The cylinder pressure are indicated.
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Problem description

Flow control Valve

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Exercise 3
Training aims
Direct actuation of a single acting cylinder Operation of a 3/2 way push button Valve with flow in normal position Realizing that DCV exist both in the normally close and normally open position Setting one way flow control valve The parcel separating device feeds parcel post from a sloping conveyor slide to an X-ray application. Operating a push button cause very rapid retraction of the single acting cylinder (1A) with the attached parcel tray. After release the valve actuator, the piston rod advances. Forward motion time = 0.9 s. a pressure gauge

Problem description

is fitted before and after the one way flow control valve.
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Pressure control Valve

a) Pressure Regulating

Valve with Relief Port

Holds working pressure, independent of pressure fluctuations in the network and the air consumption The inlet pressure must higher than working pressure If the working pressure increases, compressed air escape through a vent hole
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Pressure control Valve

a) Pressure Sequence

Valve
As a pneumatic relay. Set when pilot port exceeds at adjusted pressure value. Reset back if the pilot pot is less than preset value.

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Exercise 4
Training aims

Indirect actuation of a double acting cylinder Operating a 5/2 way double pilot valve Use of a 3/2 way push button valve Connecting up pressure gauge A plastic component is embossed using a die driven by a double acting cylinder. The die is to advanced and emboss the plastic when a push button is operated. The return of the die is to be effected when a preset pressure is reached. The embossing pressure is to be adjustable.

Problem description

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ADDITIONAL PNEUMATIC SYSTEM COMPONENT

TIMER COUNTER SENSOR BASIC SEQUENCE IDLE ROLLER
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