AN

MICRO PROJECT REPORT

ON

PNEUMATIC CIRCUITS FOR DOUBLE ACTING

CYLINDER
Submitted in partial fulfillment of the requirements of the award MSBTE Program of
Diploma
in

MECHANICAL ENGINEERING
by
Tejas Sunil Hambir

(Enrollment No. :2017340035)

UNDER THE GUIDANCE OF

PROF. PRABHAKAR SHINDE SIR

DEPARTMENT OF MECHANICAL ENGINEERING

KJEI’s

Trinity Polytechnic Pune

PUNE-411048

(2022 - 2023)

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 KJEI’s

Trinity Polytechnic Pune

Sr. No. 25 &27, Near Bopdeo Ghat, Kondhawa Saswad Road,
Dist. Pune

CERTIFICATE
This is to certify that Mr. Tejas Sunil Hambir Enrollment No.2017340035 of Sixth Semester of
Diploma in Mechanical Engineering of Institute KJEI’s Trinity Polytechnic Pune (Institute Code
: 1734) has completed term work satisfactorily in Course industrial hydraulics and pneumatics
(Course Code : 22655 ) for the academic year 2022 to 2023 as prescribed in the curriculum of
Maharashtra State Board of Technical Education (MSBTE).

Place : Pune Enrollment No.: 2017340035

Date :

Course Teacher Head of Department Principal

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 ACKNOWLEDGEMENT

I am thankful to my guide and mentor Prof. Prabhakar shinde sir for giving me an opportunity to
work under him and guide in Industrial hydraulics and pneumatics

I am thankful to Prof. PRABHAKAR SHINDE Head of Department of Mechanical Engineering,

for his motivating and valuable support throughout the course.

Mr. Tejas Sunil Hambir

(Enrollment No. 2017340035)

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 CONTENTS Page No.
1. process boilers 5
1.1 Process Boilers used in various Industries 5
1.2 Working of Process Boiler 6
1.3 The use of process boiler systems in practice Food 6
industry
2. Steam condensate 7
2.1 Difference between steam and condensate 7
2.2 Steam Loop 8
2.3 Steam Trap 8
2.4 Working of Steam Trap 8
2.5 Types of Steam Traps 9
3. Introduction to Ultra Super Critical Boilers 9
3.1 Difference between supercritical and ultra 10
supercritical
4. Conclusion 12

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1. Pneumatic circuit and pneumatic circuit diagram

Pneumatic control systems can be designed in the form of pneumatic circuits. A pneumatic circuit
is formed by various pneumatic components, such as cylinders, directional control valves, flow
control valves, pressure regulator, signal processing elements such as shuttle valve, two pressure
valve etc. Pneumatic circuits have the following functions

• To control the entry and exit of compressed air in the cylinders.

• To use one valve to control another valve
• To control actuators or any other pneumatic devices

A pneumatic circuit diagram uses pneumatic symbols to describe its design. Some basic rules
must be followed when drawing pneumatic diagrams. To be able to design pneumatic circuits, it
is better for one to have basic knowledge on the designing simple pneumatic circuits. With this
foundation, one would be able to move on to the designing more complicated circuits involving
many more cylinders.

2. DIRECT CONTROL OF DOUBLE ACTING CYLINDER

The only difference between a single acting cylinder and a double acting cylinder is that a double
acting cylinder uses a 5/2 directional control valve instead of a 3/2 directional control valve
(Figure 1.11). Usually, when a double acting cylinder is not operated, outlet ‘B’ and inlet ‘P’ will
be connected. In this circuit, whenever the operation button is pushed manually, the double
acting cylinder will move back and forth once in order to control the speed in both directions,
flow control valves are connected to the inlets on both sides of the cylinder.

The direction of the flow control valve is opposite to that of the release of air by the flow control
valve of the single acting cylinder. Compared to the throttle inlet, the flow control valve is tougher
and more stable. Connecting the circuit in this way allows the input of sufficient air pressure and
energy to drive the piston.

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Fig.2 Direct control of double acting cylinder

3. INDIRECT CONTROL OF DOUBLE ACTING CYLINDER USING MEMORY VALVE

When the 3/2-way valve meant for Forward motion (Figure 1.14b) is pressed, the 5/2 memory
valve switches over through the signal applied to its pilot port 14. The piston travels out and
remains in the forward end position. Double piloted valve is also called as the Memory valve
because now even if this push button meant Forward is released the final 5/2 control valve
remains in the actuated status as the both the pilot ports of 5/2 valves are exposed to the
atmosphere pressure and the piston remains in the forward end position. When the 3/2-way
valve meant for return motion (Figure 1.14a) is pressed, the 5/2-way valve switches back to initial
position through the signal applied to its pilot port 12.

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Fig.3 Indirect control of double acting cylinder using memory valve

The piston then returns to its initial position and remains in the rear end position. Now even if
the Return push button is released the status of the cylinder will not change. MEMORY valve
RETURN FORWARD FORWARD 2 SUPPLY 2 RETURN 5 4 14 MEMORY valve 12 2 1 3 1 3 1 3 2 2 5 4
14 12 2 1 3 1 3 1 3 a) Signal from the valve “Return” b) Signal from the valve “Forward” The circuit
is called a memory circuit because it uses a 5/2-way double pilot memory valve. 5/2-way valve
can remember the last signal applied in terms of the position of the spool in the absence of reset
springs, thus memorising or storing the pneumatic signal. Double piloted 4/2-way valve also can
be used as memory valve.

4. SUPPLY AIR THROTTLING AND EXHAUST AIR THROTTLING

It is always necessary to reduce the speed of cylinder from maximum speed based on selected
size of final control valve to the nominal speed depending on the application. Speed control of
Pneumatic Cylinders can be conveniently achieved by regulating the flow rate supply or exhaust
air. The volume flow rate of air can be controlled by using flow control valves which can be either
two-way flow control valve or one way flow control valve There are two types of throttling circuits
for double acting cylinders:

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 • Supply air throttling
• ii) Exhaust air throttling

4.1 Supply air throttling

This method of speed control of double acting cylinders is also called meter –in circuit. For supply
air throttling, one way flow control valves are installed so that air entering the cylinder is
throttled. The exhaust air can escape freely through the check valve of the throttle valve on the
outlet side of the cylinder. There is no air cushion on the exhaust side of the cylinder piston with
this throttling arrangement. As a result, considerable differences in stroking velocity may be
obtained even with very small variations of load on the piston rod. Any load in the direction of
operating motion will accelerate the piston above the set velocity. Therefore, supply air throttling
can be used for single acting and small volume cylinders.

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4.2 Exhaust air throttling.

This method of speed control of double acting cylinders is also called meter-out. In exhaust air
throttling throttle relief valves are installed between the cylinder and the main valve in such a
way that the exhaust air leaving the cylinder is throttled in both directions of the motion of the
cylinder.

Fig 4.2 Exhaust air throttling

The supply air can pass freely through the corresponding check valves in each case. In this case,
the piston is loaded between two cushions of air while the cylinder is in motion and hence a
smooth motion of the cylinder can be obtained. The first cushion effect is due to supply air
entering the cylinder through check valve, and second cushion effect is due to the exhaust air
leaving the cylinder through the throttle valve at a slower rate. Therefore, exhaust air throttling
is practically used for the speed control of double acting cylinders. Arranging throttle valves in
this way contributes substantially to the improvement of feed behaviour.

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5. VARIOUS METHODS OF CHECKING END POSITION OF A CYLINDER

The following methods are commonly used to know the end positions of piston in the cylinder:

a) Mechanically operated limit switches

• Roller lever type

• Idle return roller type

b) Reed sensors -Normally used in cylinder with magnetically coupled slide

• With Electrical output

• With pneumatic output

c) Electrical proximity switches

d) Pneumatic Signal generators

6. Use of Limit Switches

S1 and S2 are the limit switches corresponding to home position and extended position. Although
they are located in the path of the movement of piston rod, normal practice is to represent the
symbol of the limit switches on either side of the 3/2-way control valve without put signals
connected to the pilot ports of the valve. pilot signals actuations are shown for clarity) The limit
switches of Roller lever type are essentially 3/2 way ball seat or disc seat type of valves handling
pneumatic signals. These are available with direct actuation type and internally pilot actuation
type versions. Limit switches of idle return roller type are used for actuation only in one direction
are used as signal elimination device in case of signal overlap.

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Use of limit switches in pneumatic circuits

7 Objectives

• Explain the function of double acting cylinder.

• Describe the main types of controlling double acting cylinder.
• Explain the difference between direct control and indirect control of single acting
cylinder.
• Explain the differences between single and double acting cylinder.
• Draw the required circuit diagram.
• Simulate the pneumatic circuit using Fluid SIM software

7.1 Double Acting Cylinder

• Double acting cylinder is considered to be as a main actuator in any pneumatic systems.

• Double acting cylinders are more expensive than single acting cylinders, but double acting
cylinders are superior to single acting cylinders by any other important measure.
• Double action cylinders are faster and stronger.

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 • In industrial applications, single action cylinders are used in few applications, but when
speed and force are important double acting cylinders are employed.

7.2 Applications of DAC

• Opening and closing doors

• Taking things off conveyor belts and putting things on conveyor belts.
• Lifting and moving packages around
• Presses and punches.

7.3 Function

Double acting cylinder is an output device that converts the pressure energy to a mechanical
energy (linear motion).

7.4 Way of Operation

Double acting cylinder as mentioned has two ports and the air is applied in both directions
(forward and backward)

7.5 Forward (Advance) Stroke

The air is supplied to port (1) and the exhaust air is forced out through port (2)

7.6 Backward (Return) Stroke

The air is supplied to port (2) and the exhaust air is forced out through port (1)

7.7 Control circuit of the double acting cylinder

The piston rod of a double-acting cylinder is to advance when a push button is operated and to
return to the initial position when the push button is released. The double-acting cylinder can
carry out work in both directions of motion, due to the full air supply pressure being available for
extension and retraction.

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8 DIRECT CONTROL

The simplest level of control for the single or double-acting cylinder involves direct control
signals. With this, the cylinder is actuated directly via a manually or mechanically actuated valve,
without any intermediate switching of additional directional control valves. If the port sizes and
the flow values of the valve are too large, the operating forces required may be too great for
direct manual operation. Reference values for limits of direct cylinder control: Cylinder with
piston diameter smaller than 40 mm Valves with connection sizes smaller than 1/4"

9 INDIRECT CONTROL

Cylinders with a large piston diameter have a high air requirement. A control element with high
nominal flow rate must be used to actuate these. If the force should prove too high for a manual
actuation of the valve, then an indirect actuation should be constructed, whereby a signal is
generated via a second smaller valve, which will provide the force necessary to switch the control
element. To achieve the indirect control, a single and/or double pilot valves will be required.

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