Automation Y3ele Sem1 Handout 3 2016 2017

HANDOUT 3
Electro-pneumatic systems
Overview : The automation systems that use electro-pneumatic technology are formed by mainly
three kinds of elements: actuators or motors, sensors or buttons and control elements like valves.
Sensors and switches are plugged as inputs and the direct control valves for the actuators are
plugged as outputs. An internal program executes all the logic necessary to the sequence of the
movements, simulates other components like counter, timer and control the status of the system.
The most used pneumatic actuation systems are electrically controlled systems. These systems are
called electro-pneumatic actuation systems.
Electro-pneumatic control system is a combination of electrical unit and pneumatic control unit both in
one unit. A number of electro-pneumatic elements are used in electro-pneumatic controls. In electro-
pneumatic circuits solenoid operated directional control valves, limit switches and pressure switches
are used. On an automation system one can find three families of components, which are sensors,
valves and actuators. A solenoid is used in pneumatic valves to act as the actuating element.
Disadvantages of Electro-Pneumatic Systems:
A number of arguments recommend the use of such systems:

 The system allows easy automation of complex industrial processes.
 The high speed of signal transmitting and processing leads to the significant enhancement of
the productivity of the automation system.
 Electric equipment costs less than pneumatic equipment.
 Significant loads are controlled with a reduced control signal.
 The loading gauge of the control equipment is reduced.
 Electronic programmers and process computers are used for the control of the system.
Disadvantages of Electro-Pneumatic Systems:
 The systems use two supply units (pneumatic and electric).
 Functioning is not allowed in flammable environments, in environments subjected to hazard of

explosion or in high humidity conditions.
 Hazard of electrocution is present.
Electro-Pneumatic Control System:
Electro-pneumatics is successfully used in many areas of industrial automation. Production, assembly and
packaging systems worldwide are driven by Electro-pneumatic control systems. The change in requirements
together with technical advances has had a considerable impact on the appearance of controls. In the signal
control section, Electropneumatic controllers have the following advantages over pneumatic control systems:
1. Higher reliability (fewer moving parts subject to wear);
2. Lower planning and commissioning effort, particularly for complex controls;
3. Lower installation effort, particularly when modern components such as valve terminals are used;
4. Simpler exchange of information between several controllers.
HAND OUT COMPILED BY Mr. Emmanuel NDAYISENGA FOR SYLLABUSES,ASSIGNMENTS AND UPDATES CHECK
ONLINE AT www.emmanuelinmp.wordpress.com Page 55
Electro-pneumatic also used for remotely controlled system where a few sensors are added to assure the safe
operation
SEVEN BASIC ELECTRICAL AND OTHER DEVICES USED IN ELECTROPNEUMATICS
Seven basic electrical devices commonly used in the control of fluid power systems are:
1) Manually actuated push button switches
2) Limit switches 3) Pressure switches
4) Solenoids 5) Relays
6)Timers 7) Temperature switches
Electro-pneumatic components
Solenoid Valves
Electrical components
SAMPLES OF ELECTROPNEUMATIC CIRCUITS
EXERCISE 1: Control of a vacuum generator using electric counter.
Setting: The vacuum generator start operating when push button S1 is pressed on five times. A magnetic field
is produced in the coil 1Y. The armature in the coil opens the passage for the compressed air. The
compressed air flows from 1 to 2 of the 3/2 electro-pneumatic DCV to cylinder, which travels to the vacuum
generator.
Resetting: When the push button S2 is pressed on, the circuit is interrupted. The magnetic field at coil 1Y
collapses, the 3/2 way valve switches back to its original position as shown in Figure below. The compressed
air in the cylinder then exhausts through port 3 of the DCV and the vacuum generator is reset to the final rear
position.
EXERCISE 2: Indirect control of a double acting cylinder
A double acting cylinder is to extend when two push buttons are operated at the same time. Upon
release of one of the push buttons the cylinder is to retract.
Exercise3 A double-acting cylinder is used to press together glued component.
Upon operation of a push button, the clamping cylinder extends. Once the fully advanced position is reached,
the cylinder is to remain a time of T= 10 seconds and then immediately retract to the initial position.
The cylinder retraction is to be adjustable. A new start cycle is only possible after the cylinder has fully
retracted.
SOLUTION:
EXERCISE 4:
Two cylinders are used to transfer parts from a magazine onto a chute. When push button is pressed,
the first cylinder extends, pushing part from the magazine and positions it in preparation for transfer
by the second cylinder onto the out feed chute. Once the part is transfer, the first cylinder retracts,
followed by the second. Confirmation of all extended and retracted positions are required.
SOLUTION:
EXERCISE 5: The same as in exercise 4 but this time we have to add the possibility of making the circuit fully
automated.
EXERCISE 6: Triple-cylinder sequence circuits
Two double-acting cylinders and one single-acting cylinder are to operate as follows:
When a start push button is momentarily pressed on, the solenoid of the first cylinder is momentarily energized
to shift the first valve, which extends cylinder 1. When cylinder 1 is fully extended; limit switch S1 is actuated,
the solenoid of the second valve is energized, which shifts the second valve into its left flow path mode. This
extends cylinder 2. As a result, solenoid of the third valve is actuated and cylinder 3 must also extend. Once
the third cylinder is fully extended, the first cylinder retracts, followed by the second one, and at last the third
one. Design the control and power circuits of this installation.
FUNCTION DIAGRAMS -GRAFCET– SFC
History
1977 – GRAFCET definition (Graphe Fonctionnel de Commande Etape-Transition).
• 1988 - GRAFCET becomes an international standard denominated as "Sequential Function Chart“,
GRAFCET GRAFCET Basic Elements
State of a GRAFCET
State Evolution:
Rule 2a: All active Transitions are transposed immediately.
• Rule 4: Simultaneous active Transitions are transposed simultaneously.
Given 4 Steps (1 to 4) and 2 Transitions (t1 and t2) write a segment of GRAFCET to solve the following problem:
In the case that the Steps 1 and 2 are active:
• if t1 is TRUE, activate Step 3 (and deactivate Steps 1 and 2);
• if t2 is TRUE, activate Step 4 (and deactivate Steps 1 and 2);
• otherwise, the state is maintained.
If Step 1 is active and t1 is TRUE

OR
If Step 2 is active and t2 is TRUE
THEN Activate Steps 3 and 4.
GRAFCET state evolution, Conflicts: There exist Conflicts when the validation of a Transition depends on the same Step
or when more than one receptivity functions can become true simultaneously.
Solutions:
Example 2: modeling a automated transport workcell
,

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HANDOUT 3

Disadvantages of Electro-Pneumatic Systems:

A number of arguments recommend the use of such systems:

Disadvantages of Electro-Pneumatic Systems:

 The systems use two supply units (pneumatic and electric).

 Functioning is not allowed in flammable environments, in environments subjected to hazard of

 Hazard of electrocution is present.

Electro-Pneumatic Control System:

1. Higher reliability (fewer moving parts subject to wear);

2. Lower planning and commissioning effort, particularly for complex controls;

4. Simpler exchange of information between several controllers.

SEVEN BASIC ELECTRICAL AND OTHER DEVICES USED IN ELECTROPNEUMATICS

1) Manually actuated push button switches

2) Limit switches 3) Pressure switches

6)Timers 7) Temperature switches

EXERCISE 1: Control of a vacuum generator using electric counter.

Exercise3 A double-acting cylinder is used to press together glued component.

EXERCISE 6: Triple-cylinder sequence circuits

1977 – GRAFCET definition (Graphe Fonctionnel de Commande Etape-Transition).

• 1988 - GRAFCET becomes an international standard denominated as "Sequential Function Chart“,

GRAFCET GRAFCET Basic Elements

Rule 2a: All active Transitions are transposed immediately.

• Rule 4: Simultaneous active Transitions are transposed simultaneously.

If Step 1 is active and t1 is TRUE

THEN Activate Steps 3 and 4.

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