PNEUMATIC

Participant Manual

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Learning Overview

This course allows trainee to acquire knowledge on basic hydraulic and pneumatic system and
its application. Technical understanding on the principles and operation of the equipment is
also emphasised during theoretical and practical sessions .

Course Learning Objectives

At the end of the session, trainees will be able to:

1. Explain the principle of hydraulics and pneumatics.

2. Identify the components of the hydraulic and pneumatic systems
3. Describe the function of the hydraulic and pneumatic component.
4. Apply the basic principles and standard symbols in developing simple hydraulic and
pneumatic systems.
5. Describe the general safety in handling hydraulic and pneumatic systems.

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Table of Contents

1.0 Principles of Pneumatics

1.1 Introduction to Pneumatics System........................................................

5
1.2 Application of Pneumatic System………………………………………………………..
5
1.3 Advantages and Disadvantages of Pneumatic System…………………………
7
1.4 Basic Law of Pneumatic System…………………………………………………………..
8
2.0 Components of Pneumatic System
12
2.1 Pneumatic Systems Configuration……………………………………………………….
13
2.2 Pneumatic system structure and signal flow..........................................
15
2.3 Air generation and distribution..............................................................
19
2.4 Valves......................................................................................................
44
2.5 Actuators................................................................................................
50
2.6 Pneumatic symbols.................................................................................
3.0 Pneumatic Circuits Diagram
65
3.1 Direct and Indirect Control of a Cylinder.
69
3.2 Logic Functions: AND, OR.
72
3.3 Memory Circuit and Speed Control of a Cylinder.
73
3.4 Quick Exhaust Valve.
73
3.5 Pressure Dependent Control.
75
3.6 Time Delay Valves.
4.0 Safety Regulation on Pneumatic System
79
4.1 General safety rules...............................................................................
82
4.2 Common hazards and remedies.............................................................
82
4.3 Working with air tools............................................................................
83
4.4 Oil and water.........................................................................................
5.0 Problem Solving and Discussion

i Exercise 1: Bending device…………………………………………………………………

85

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 ii Exercise 2: Separating product from a magazine……………………………….. 86
iii Exercise 3: Automatic washing machine……………………………………………. 87

CHAPTER 1

PRINCIPLES OF PNEUMATICS

Learning Objectives

At the end of the topic, trainees will be able to:

1. Explain what pneumatic system is.

2. List five applications of pneumatic system.
3. Discuss the advantages and disadvantages of the pneumatic system.
4. Identify the unit of pressure.
5. Convert unit of pressure.

References
1. Hydraulic & Pneumatic; McGraw-Hill 2010
2. Pneumatic Basic Level FESTO, 2002

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Chapter 1 Principles of Pneumatics

1.1 Introduction to Pneumatics system

Pneumatic system uses pressurized gases to transmit and control power. As the name
implies, pneumatic systems typically use air as fluid medium because air is safe, low cost and
readily available fluid. It is particularly safe in environments where an electrical spark could
ignite leaks from system components.

There are several reasons for considering the use of pneumatic system instead of hydraulic
system. Liquids exhibit greater inertia than do gases. Therefore, in hydraulic system the weight
of oil is a potential problem when accelerating and decelerating actuators and when suddenly
opening and closing valves.

Due to Newton's law of motion (force equals mass multiplied by acceleration), the force
required to accelerate oil is many times greater than that required to accelerate an equal volume
of air. Liquids also exhibit greater viscosity than do gases.

This results in larger frictional pressure and power losses. Also, since hydraulic system
uses a fluid foreign to the atmosphere, they require special reservoirs and no-leak system
designs. Pneumatic system uses air that is exhausted directly back into the surrounding
environment. Generally speaking, pneumatic system is less expensive than hydraulic system.

1.2 Application of Pneumatic System.

Pneumatic systems can perform the following types of motions:-

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 i. Linear.
ii. Swivel.
iii. Rotary.

The applications of pneumatic systems are:-

i. General methods of material handling, including,

 clamping
 shifting
 positioning
 orienting

ii. Others applications including,

 packaging
 feeding
 metering
 door or chute control
 sorting parts
 stacking of components.

Pneumatic systems are also used in carrying out machining and working operations, for
example,
 drilling
 turning
 milling
 sawing
 finishing
 forming.

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1.3 Advantages and Disadvantages of Pneumatic System

1.3 1 Advantages of Pneumatic System

Many factors control whether or not pneumatic systems should be used in an

application. To understand more about these factors, let's first explore the major
advantages that compressed air offers over either hydraulic or electric motors.

a) Fluid availability - air is the most used gas in pneumatic systems and is readily
available directly from the atmosphere. Hydraulics, on the other hand, uses
expensive liquids.
b) Storage - a compressor need not be in continuous operation. Compressed air
can be stored in a reservoir and removed as required. In addition, the reservoir
can be transportable.
c) Cleanliness – un-lubricated exhaust air is clean. Any un-lubricated air which
escape through leaking pipes or components does not cause contamination.
This is an important point when considering the food, wood and textile
industries.
d) Low cost - cost generally is an advantage that pneumatics has over hydraulics
because of air availability, the low pressures and circuit simplicity. However cost
is dependent on many factors and each must be considered to determine if
pneumatics is cost effective.
e) Explosion proof - compressed air offers minimal risk of explosion or fire, hence
no expensive protection against explosion is required.
f) Temperature - compressed air is relatively insensitive to temperature
fluctuations. This ensures reliable operation, even under extreme conditions.

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 g) Overload safe - pneumatic tools and operating components can be loaded to the
point of stopping and are therefore overload safe

1.3 2Disadvantages of Pneumatic System

All methods of power transmission have disadvantages. The five disadvantages of
pneumatics are:-

a) Conditioning required - moisture and dirt can cause erratic pneumatic system
operation. When using air, conditioning to remove most moisture and dirt is
required for dependable operation.
b) Noisy - compressed air exhausting from pneumatic components can be very
noisy. In areas where noise cannot be tolerated, pneumatic equipment is not
used unless special dampening equipment is used.

c) Cost - compressed air is a relatively expensive means of conveying power. The

high energy costs are partially compensated by inexpensive components and
higher performance.
d) Limited force - most pneumatics systems use compressed air and therefore
operate at low pressure. As a result, force and power levels are limited.
Hydraulic, on the other hand, can operate at high pressures providing high force
and power levels.
e) Compressible - it is not always possible to achieve uniform and constant piston
speeds with compressed air.

1.4 Basic Law of Pneumatic System

The basic laws of pneumatic systems consist of the Pascal's law related to pressure
delivery, and Boyle's law relating to volume and pressure.

i. Pascal's law.
a.The Pascal's law stated that "the pressure applied to part of the static fluid in a closed
container vertically acts on the entire area of the fluid".
ii. Boyle's law.

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 a.Boyle's law stated that " at constant temperature, the volume of a given mass is inversely
proportional to the absolute pressure".

Figure 1.1: Boyle's law - pressure and volume relationship

p1.V1 = p2.V2 = p3.V3 = constant

1.4 1 Pressure
1 Pascal is equal to the constant pressure on a surface area of 1m 2 with the vertical
force of 1 N (Newton). 100kPa is equal to 14.5 psi (pounds per square inch). Since
everything on earth is subjected to the absolute atmospheric pressure (p at), this pressure
cannot be felt.
The prevailing atmospheric pressure is therefore regarded as the base and any
deviation is termed:-

Gauge Pressure = pg
or
Vacuum = pv

The atmospheric pressure does not have a constant value. It varies with the
geographical location and the weather. The range from the absolute zero line to the variable
atmospheric pressure line is called the vacuum range and above this, the pressure range.

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 The absolute pressure, pab is composed of pressure pat and pressure pg. In practice,
gauges are used which show only the excess pressure, p g. Pressure pab is approximately 1
bar (100 kPa) greater than the Pg value.

Pressure measurement.

Pressure = Force/Area
P = F/A
Unit of pressure:-
 Bar
 Psi
 kg/cm2
 N/m2
 kgf/cm2
 pascal
 kPa

Conversion factor:-
1 N/m2 = 1 pascal
1 kg/cm2 = 1 bar
100,000 N/m2 = 1 bar
1 psi = 6895 N/m2
1 bar = 14.5 psi

EXERCISE

1. Define the pneumatic systems.

2. List five applications of pneumatic systems.
3. Give three types of motions can be performed by pneumatic systems.
4. List five advantages of pneumatic.
5. List five disadvantages of pneumatic.
6. Give five units of pressure.
7. Covert the following unit of pressure:-
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 (i) 1 N/m2 = pascal.
(ii) 1 bar = N/m2
(iii) 1 psi = N/m2
(iv) 1 bar = psi

CHAPTER 2

COMPONENTS OF PNEUMATIC SYSTEM

Learning Objectives

At the end of the topic, trainees will be able to:

1. Discuss about the pneumatic systems configuration.

2. Explain the pneumatic systems structure and signal flow.
3. List down at least five aspects should be considered during the preparation of the service
air.
4. Describe about the air supply section.
5. Explain the components of air service unit and their functions.
6. Describe the purpose, construction and operation of various types of valves.
7. Differentiate between spool and poppet valves.
8. Explain the valve operation methods.
9. Discuss about the pneumatic actuators.

References
3. Hydraulic & Pneumatic; McGraw-Hill 2010,

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Chapter 2 Components of Pneumatic System

2.1 Pneumatic Systems Configuration

Basically, the pneumatic system is composed of six to ten functions and components, and
systems are generally connected as shown in figure 1.

Figure 2.1: Pneumatic systems configuration

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2.2 Pneumatic system structure and signal flow.

A pneumatic system can be divided into a number of levels representing hardware and
signal flow. The various levels form a control path for signal flow the signal (input) side to the
work (output) side.

Figure 2.2: Signal flow.

The primary levels in pneumatic systems are:-

i. Energy supply
ii. Input elements (sensors)
iii. Processing elements (processors)
iv. Actuating devices (actuators)

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 The elements in the system are represented by symbols which indicate the function of the
element. The symbols can be combined to represent a solution for a particular control task
using the circuit diagram.

The circuit is drawn with the same structure as the signal flow diagram above. At the
actuator level the addition of the control element completes the structure. The control
element controls the action of the actuator after receiving signals sent by the processor
elements.

Figure 2.3: Pneumatic elements.

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 The directional control valve (DCV) may have a sensing, a processing or an actuating
control function. If the DCV is used to control a cylinder motion, then it is a control element for
the actuator group. If it is used in the function of processing signals, then it is defined as a
processor element. If it is used to sense motions, then it is defined as a sensor.

The distinguishing feature between each of these roles is normally the method of
operating the valve and where the valve is situated in the circuit diagram.

1.0 1.3

1.1

1.6

1.3
1.2 1.4

0.1

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 Figure 2.4: Circuit diagram and pneumatic elements

2.3 Air generation and distribution

The air supply for a particular pneumatic applications should be sufficient and of adequate
quality. Air is compressed to approximately 1/7th. of its volume by the air compressor and
delivered to an air distribution system in the factory.

To ensure the quality of the air is acceptable, air service equipment is utilized to prepare
the air before being supplied to the control system

2.5.1 Preparation of Air Services

Malfunctions can be considerably reduced in the system if the compressed air is
correctly prepared. Several aspects should be considered in the preparation of the service
air:-
i. Quantity of air required to meet the demands of the system.
ii. Type of compressor to be used to produce the quantity required.
iii. Storage required.
iv. Requirements for air cleanliness.
v. Acceptable humidity levels to reduce corrosion and sticky operation.
vi. Lubrication requirements, if necessary.
vii. Low temperature of the air and effects on the system.
viii. Pressure requirement.
ix. Line sizes and valve sizes to meet demand.
x. Material selection and system requirements for the environment.
xi. Drainage points and exhaust outlets in the distribution system
xii. Layout of the distribution system to meet demand.

As a rule, pneumatic components are designed for a maximum operating

pressure of 8 - 10 bar (800 - 1000 kPa) but in practice it is recommended to operate at
between 5 and 6 bar (500 - 600 kPa) for economic use.

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 Due to the pressure losses in the distribution system the compressor should
deliver between 6.5 and 7 bar (650 - 700 kPa) to attain these figures.

An air receiver should be fitted to reduce pressure fluctuations. In normal

operation the compressor fills the receiver when required and the receiver is available as
a reserve at all times. This reduces the switching cycles of the compressor.

Figure 2.5: Air supply system.

If oil is required for the pneumatic system then this should be separately metered
using air service equipment. In a normal situation, components should be selected for the
control system that do not require lubrication

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2.5 2 Air Service Unit

The air service unit is a combination of the following:-

i. Air filter
ii. Air regulator
iii. Air lubricator

Figure 2.6: Air service unit.

An air service unit is fitted at each control system in the network to ensure the
quality of air for each individual task.

Air filter.

The function of air filter is to remove all contaminants from the compressed air
flowing through it as well as water which has already condensed. Liquid particles and
larger particles of dirt are separated centrifugally collecting in the lower part of the filter
bowl. The collected condensate must be drained before the level exceeds the maximum
condensate mark, as it will otherwise be re-entrained in the air stream.

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 Air regulator.

The function of air regulator is to keep the operating pressure virtually constant
regardless of fluctuations in the line pressure and the air consumption.

Air lubricator.

The function of air lubricator is to deliver a metered quantity of oil mist into a leg
of the air distribution system when necessary for the use by pneumatic control and
working components.

2.4 Valves

Valves can be divided into a number of groups according to their function in relation to
signal type, actuation method and construction. The primary function of the valve is to alter,
generate or cancel signals for the purpose of sensing, processing and controlling.

The valves are categories as:-

i. Directional control valves

ii. Non-return valves
iii. Flow control valves
iv. Pressure control valves
v. Combination valves.

2.4 1 Pneumatic valve structure.

Pneumatic changeover valves can be divided into:-
i. Spool or slide valves.
In spool or slide valves, the individual connections are linked together or
closed by means of spool slides, spool flat slides or sliding disc valves.

ii. Poppet valves.

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 With poppet valves the connections are opened and closed by means of
balls, discs, plates or cones. The valve seats are usually sealed simply using
elastic seals. Seat valves have few parts which are subject to wear and hence
they have a long service life. They are insensitive to dirt and are robust. The
actuating force, however, is relatively high as it is necessary to overcome the
force of the built-in reset spring and the air pressure.

Figure 2.7: Spool and poppet valves

2.4 2 Valves operation methods.

Operation system of the pneumatic changeover valves is classified into the

following:-

i. Electronic (electric) operation.

 This valve is operated through the use of electromagnet, and is
generally called solenoid valves.

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 ii. Man-powered operation.
 These type of valves are visually checked and operate by man-
power, and such types include manual valves or foot pedal valves.
iii. Mechanical operation.
 These types of valves are operated by applying mechanical force
from external sources, such as cam and links.
iv. Pneumatic operation.
 These type of valves use air pressure to operate, and are used in
places where electricity cannot be used (such as places where
explosive gas is existing, or places where there is risks of leakage
due to presence of water).

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 Figure 2.8: Classification of operation system divided into manpower
operation system and mechanical system.

2.4 3 Directional Control Valves

The directional control valve controls the passage of air signals by generating,
canceling or redirecting signals.

The way valve is described by:-

i. Number of ports or openings (ways) : 2 way, 3 way, 4 way, 5 way, etc.

ii. Number of positions : 2 positions, 3 positions, etc.
iii. Methods of actuation of the valve : manual, air pilot, solenoid, etc.
iv. Methods of return actuation : spring return, air return, etc.
v. Special features of operation : manual overrides, etc.

Directional control valves are devices which influence the path taken by an air
stream. Normally this involves one or all of the following: opening the passage of air and

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 directing it to particular air lines, cancelling air signals as required by blocking their
passage and/or relieving the air to atmosphere via an exhaust port.

The directional control valve is characterized by its number of controlled

connections or ways, the number of switching positions and the method of actuation.
However, these symbols do not provide any information about the constructional design,
but merely indicate the function of the valve.

The normal position on valves with existing reset, e.g. spring, refers to the
switching position assumed by the moving parts of the valve, if the valve is not connected.
The initial position is the switching position assumed by the moving parts of a valve after
the valve has been installed in a system and the system pressure has been switched on
and possibly also the electrical voltage, and with which the designated switching program
starts.

The constructional principle of a directional control valve is an important factor as

far as the service life, switching time, type of actuation, connection methods and size are
concerned.

Designs are categorized as follows:

 Poppet valves:
o Ball seat valve
o Disc seat valve
 Slide valves :
o Longitudinal slide valve (spool valve)
o Longitudinal flat slide valve
o Plate slide valve

2/2 way valve.

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 The 2/2 way valve has two ports and two positions. It is rarely used except as an
on/off valve, since its only function is to enable signal flow through and cannot release the
air to atmosphere once in the closed position.

If air is to be released on closing, then the 3/2 way valve must be used. The 2/2
way valve is normally of the ball seat construction similar to the 3/2 way valve. It is
generally manually operated or pneumatically operated.

3/2 way valve.

The 3/2 way valve is a signal generating valve, with the characteristic that a signal
on the output side of the valve can be generated and also canceled. The 3/2 way valve
has three ports and two positions. The additions of the exhaust port 3(R) enables the
signal generated via the passage through the 3/2 way valve to be canceled. The valve
connects the output signal 2(A) to exhaust 3(R) and atmosphere in the initial position.

The example of 3/2 way valves are:-

i. 3/2 way roller lever valve: with and without idle return.

(a) (b)

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 Figure 2.9: (a) 3/2 way roller lever valve: with and without idle return & (b) 3/2-way valve,
normally closed, ball seat

ii. 3/2 way valve single pilot

Figure 2.10: 3/2 way valve single pilot

4/2 way valve.

The 4/2 way valve has four ports and two positions.

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 Figure 2.11: 4/2 way valve: disc seat, un-actuated.

A disc seat 4/2 way valve is similar in construction to the combination of two 3/2
way valves, one valve normally closed and the other normally open. When the two
plungers are actuated simultaneously, 1(P) to 2(B) and 4(A) to 3(R) are closed by the first
movement.

By pressing the valve plungers further against the discs, opposing the reset spring
force, the passages between 1 (P) to 4(A) and from 2(B) to 3(R) are opened. The plungers
can be operated by an auxiliary mounted device such as a roller arm or pushbutton.

The valve has a non-overlapping exhaust connection and is returned to its start
position by the spring. The valves are used for controls employing double-acting
cylinders.

There are other actuating methods and types of construction available for the 4/2
way valve including pushbutton, double air pilot, roller lever operated, spool and sliding
plate. The 4/2 way valve is utilized in similar roles as the 5/2 way valve.

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 Figure 2.12: 4/2 way valve: disc seat, actuated

5/2 way valve.

The 5/2 way valve has five ports and two positions. The 5/2 way valve is used
primarily as a final control element for the control of cylinders. An example of the 5/2 way
valve, the longitudinal slide valve, uses a pilot spool as a control component. This
connects or separates the corresponding lines by means of longitudinal movements. The
required actuating force is lower because there are minimal opposing forces due to
compressed air or spring.

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 Figure 2.13: 5/2 way valve: double pilot valve.

The 5/2 way double air pilot valve has the characteristic of memory control. The
last switched position is retained until a new switching position is initiated by a unique
pilot signal from the opposite side to the last signal. This new position is memorized until
another unique signal occurs.

Reliable operation of valves

i. Mounting of roller lever valves:

The reliability of a control sequence is heavily dependent upon the correct fitting
of the limit valves. For all designs of limit valves the mounting must allow simple
adjustment or readjustment of the limit valve position in order to achieve precise co-
ordination of the cylinder motions within a control sequence.

ii. Fitting of valves:

Apart from a careful selection of valves, correct fitting is a further prerequisite for
reliable switching characteristics, trouble-free operation and easy access for repair and
maintenance work. This applies both to valves in the power section and valves in the
control section.

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 iii. Maintenance and repairs are facilitated by:
 Numbering of components
 Incorporation of visual displays
 Comprehensive documentation

Manually-actuated valves for signal input are generally fitted on a control panel or
control desk. It is therefore practical and convenient to use valves with actuators that can
be fitted onto the basic valve. Various actuators are available for a wide variety of input
functions.

Valves in the form of control elements control the sequence of pneumatic power
components. They need to be constructed in such a way as to trigger as fast a reaction of
the actuators as possible. The power valve should therefore be positioned as closely as
possible to the actuator in order to keep line lengths, and thus switching times, as short as
possible.

Ideally, the power valve should be fitted directly to the drive. An additional
advantage of this is that connectors, tubing and assembly time can be saved.

2.4 4 Non-return Valves

The non-return valve allows a signal to flow through the device in one direction
and blocks the flow in the other direction. There are many variations in construction and
size derived from the basic non-return valve. Other derived valves utilized features of the
non-return valve by the incorporation of non-return elements. The non-return valve can
be found as an element of the one way flow control valve, quick exhaust valve, shuttle
valve and the dual-pressure valve.

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 Figure 2.14: Non-return valve and its derivatives

Check valves.

Check valves can stop the flow completely in one direction. In the opposite
direction the flow is free with a minimal pressure drop due to the resistance of the
valve. Blocking of the one direction can be effected by cones, balls, plates or diaphragms.

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 Figure 2.15: Check valve

Dual-pressure valve (Logic AND Function)

The dual pressure valve has two inlets 1 and 1(3) and one outlet 2. Compressed air
flows through the valve only if signals are applied to both inlets. One input signal at 1 or
1(3) blocks the flow due to the differential forces at the piston slide. If signals are applied
to both 1 and 1(3), the signal which is last applied passes to the outlet.

If the input signals are of different pressures, the larger of the two pressures closes
the valve and the smaller air pressure is transferred to the outlet 2.

The dual pressure valve is used mainly for;

i. interlocking controls,
ii. safety controls,
iii. check functions and
iv. logic AND operations.

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 Fig.2.16: Dual pressure valve: logic AND function

Fig. 2.17: Circuit diagram with dual pressure valve

Shuttle valve (Logic OR function)

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 This non-return element has two inlets 1 and 1(3) and one outlet 2. If compressed
air is applied to the first inlet 1, the valve seat seals the opposing inlet 1(3), the air flows
from 1 to 2. Inlet 1 is closed, if air passes from 1(3) to 2.

A signal is generated at the outlet. When the air flow is reversed, i.e. a cylinder or
valve is exhausted, the seat remains in its previously assumed position because of the
pressure conditions.

This valve is also called an OR element. If a cylinder or control valve is to be

actuated from two or more positions, one or more shuttle valves should be used.

Fig 2.18: Shuttle valve: logic OR function

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 In the example shown, a cylinder is to be advanced using two hand operated
valves, which can be fitted at different distances from the cylinder. Without the use of the
shuttle valve, the compressed air would mainly flow via port 3 of the valve 1S2, if the
valve 1S1 is actuated.

Fig. 2.19: Controlling a cylinder with two input elements

Quick exhaust valve.

Quick-exhaust valves are used to increase the piston speed of cylinders. This
enables lengthy return times to be avoided, particularly with single acting cylinders. The
principle of operation is to allow the cylinder to retract at its near maximum speed by
reducing the resistance to flow of the exhausting air during motion of the cylinder.

To reduce resistance, the air is expelled to atmosphere close to the cylinder via a
large orifice opening. The valve has a closable supply connection 1, a closable exhaust 3
and an outlet 2.

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 Fig. 2.20: Quick exhaust valve: flow from 1 to 2

If pressure is applied at port 1, then the sealing disc covers the exhaust 3, whereby
the compressed air passes from 1 to 2. If pressure is no longer applied at 1, then the air
from 2, moves the sealing disc against port 1 and closes this, whereby the exhaust air
immediately vents to atmosphere.

There is no need for the air to pass through a long and possibly restricted path to
the directional control valve via the connecting lines. It is advantageous to mount the
quick-exhaust valve directly on the cylinder or as near to it as possible.

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 Figure 2.21: Quick exhaust valve: exhaust from 2 to 3

2.4 1 Flow Control Valves

The flow control valve restricts or throttles the air in a particular direction to
reduce the flow rate of the air and hence control the signal flow. If the flow control valve
is left wide open then the flow should be almost the same as if the restrictor is not fitted.

Figure 2.22: Flow control valve

Flow control valve (Throttle valve)

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 Flow control valves influence the volumetric flow of the compressed air in both
directions. The throttle valve is a flow control valve.

Throttle valves are normally adjustable and the setting can be locked in position.
Throttle valves are used for speed control of cylinders. Care must be taken that the
throttle valve does not close fully, cutting off air from the system.

Due to the compressibility of air, the motion characteristics of a cylinder vary with
load and air pressure.

Therefore, flow control valves are used for speed control of cylinders within a
range of values. Care must be taken that the flow control valve is not closed fully, cutting
off air from the system. The open flow setting should be locked in place.

Figure 2.23: Throttle valve

Characteristics of flow control valves according to construction principle:

 Throttle valve:
In the throttle valve, the length of the throttling section is greater than

its diameter.

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  Diaphragm valve:
In the diaphragm valve, the length of the throttling section is less than its
diameter

One-way flow control valve

In one way flow control valve, the air flow is throttled in one direction only. A check valve
blocks the flow of air in the bypass leg and the air can flow only through the regulated
cross-section. In the opposite direction, the air can flow freely through the opened check
valve. These valves are used for speed regulation of actuators and if possible, should be
mounted directly on the cylinder.

Fig. 2.24: One-way flow control valve

2.4 1 Pessure Control Valves

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 Pressure control valves are utilized in pneumatic systems. There are three main
group:-

(i) Pressure regulating valves

(ii) Pressure limiting valves
(iii) Pressure sequence valves.

Pressure regulating valve

The pressure regulating valve controls the operating pressure in a control circuit
and keeps the pressure constant irrespective of any pressure fluctuations in the system.

Figure 2.25: Pressure regulating valve

Pressure limiting valve

The pressure limiting valves are used mainly as safety valves (pressure relief
valves). They prevent the maximum permissible pressure in a system from being
exceeded. If the maximum pressure has been reached at the valve inlet, the valve outlet is

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 opened and the excess air pressure exhausts to atmosphere. The valve remains open until
it is closed by the built-in spring after reaching the pre-set system pressure.

Pressure sequence valve

The principle on which this valve acts is the same as for the pressure limiting valve.
If the pressure exceeds that set on the spring, the valve opens. The flow from 1 to 2 is
closed. Outlet 2 is opened only if a preset pressure has built up in pilot line 12. A pilot
spool opens the passage 1 to 2.

Figure 2.26: Adjustable pressure sequence valve.

Pressure sequence valves are installed in pneumatic controls where a specific

pressure is required for a switching operation (pressure dependent controls).

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 Figure 2.27: Circuit diagram with pressure sequence valve

2.4 5 Combinational Valves

The combined functions of various elements can produce a new function. The new
component can be constructed by the combination of individual elements or
manufactured in a combined configuration to reduce size and complexity.

An example is the timer which is the combination of a one way flow control valve,
a reservoir and a 3/2 way directional control valve. The time delay valve can be with 3/2
way valve normally closed or normally open. The delay time is generally 0 - 30 seconds for
both types of valves. By using additional reservoirs, the time can be extended.

Components of different control groups can be combined into the body of one unit
with the features, characteristics and construction of a combination of valves. These are
referred to as combinational valves and their symbols represent the various components
that make up the combined unit. The following units can be defined as combinational
valves:

i. Time delay valves: for the delay of signals

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 ii. Air control blocks: for the execution of individual and oscillating
movements using double-acting cylinders
iii. 5/4-way valve: for the stopping of double-acting cylinders in any position
iv. Air operated 8-way valve: for the control of feed units
v. Pulse generator: for the execution of rapid cylinder movements
vi. Vacuum generator with ejector: for pick and place applications
vii. Stepper modules: for sequential control tasks
viii. Command memory modules: for startup with signal input conditions

Time Delay Valve

The time delay valve is a combined 3/2-way valve, one way flow control valve and
air reservoir. The 3/2-way valve can be a valve with normal position open or closed. The
delay time is generally 0-30 seconds for both types of valves.

By using additional reservoirs, the time can be extended. An accurate switch-over

time is assured, if the air is clean and the pressure relatively constant.

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 Fig. 2.28: Time delay valve:

The valve spring returns the pilot spool and the valve disc normally closed

The following operational principle applies for a time delay valve with a 3/2-way
valve in normally closed position:

 The compressed air is supplied to the valve at connection 1.

 The control air flows into the valve at 12 through a one-way flow control valve and
depending on the setting of the throttling screw, a greater or lesser amount of air
flows per unit of time into the air reservoir.
 When the necessary control pressure has built up in the air reservoir, the pilot spool
of the 3/2-way valve is moved downwards.
 This blocks the passage from 2 to 3. The valve disc is lifted from its seat and thus air
can flow from 1 to 2.
 The time required for pressure to build up in the air reservoir is equal to the control
time delay of the valve.
 If the time delay valve is to switch to its initial position, the pilot line 12 must be
exhausted.
 The air flows from the air reservoir to atmosphere through the bypass of the one-
way flow control valve and then to the exhaust line.
 seat to their initial positions. Working line 2 exhausts to 3 and 1 is blocked.

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 Figure 2.29: Time delay valve: normally open

The normally open time delay valve includes a 3/2-way valve which is open. Initially
the output 2 is active. When the valve is switched by 10 the output 2 is exhausted to 3 and
1 is closed. The result is that the output signal is turned off after a set time delay.

The time delay corresponds to the pressure build up in the reservoir

again. If the air at port 10 is removed, then the 3/2-way valve assumes

the normal position.

The circuit below utilizes two time delay valves, one a normally closed valve (1V2)
and the other a normally open valve (1V1). Upon operation of the start button 1S1, the

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 signal generated passes through the valve 1V1 and initiates the movement of cylinder
extension (1A) via the 14 port of the control element 1V3.

The time delay valve 1V1 has a short time delay set of 0.5 seconds. This is long
enough to initiate the start signal but then the 14 signal is cancelled by the 10 pilot signal
of the time delay valve. The cylinder operates limit valve 1S2.

The time delay valve 1V2 receives a pilot signal which after the preset time opens
the valve. This supplies the 12 signal which reverses the valve and retracts the cylinder. A
new cycle can only be started via the start button and renewed actuation of the valve 1S1.

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 Figure 2.30: Circuit diagram with time delay valve

2.5 Actuators

An actuator is an output device for the conversion of supply energy into useful work. The
output signal is controlled by the control system, and the actuator responds to the control
signals via the control element. Other types of output devices are used to indicate the status of
the control system or actuators, e.g. a pneumatically actuated visual display.

The power section consists of control elements and power components or actuators. The
actuator group includes various types of linear and rotary actuators of varying size and
construction. The actuators are complemented by the control elements, which transfer the
required quantity of air to drive the actuator. Normally this valve will be directly connected to
the main air supply and fitted close to the actuator to minimize losses due to resistance.

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 Figure 2.31: Actuator with control element

Actuators can be further broken down into groups:

 Linear actuators
o Single-acting cylinder
o Double-acting cylinder
 Rotary actuators
o Air motors
o Rotary actuators

Figure 2.32: Actuators, linear and rotary

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 2.5 1 Single Acting Cylinder

Figure 2.33: Single acting cylinder

With single-acting cylinders compressed air is applied on only one side of the
piston face. The other side is open to atmosphere. The cylinder can produce work in only
one direction.

The return movement of the piston is effected by a built-in spring or by the

application of an external force. The spring force of the built-in spring is designed to
return the piston to its start position with a reasonably high speed under no load
conditions.

For single-acting cylinders with built-in spring, the stroke is limited by the natural
length of the spring. Single-acting cylinders are therefore only available in stroke lengths
of up to approximately 80 mm. The construction and simplicity of operation of the single-
acting cylinder makes it particularly suitable for compact, short stroke length cylinders for
the following types of applications:

 Transferring

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  Branching
 Converging
 Allocating
 Clamping
 Ejecting

2.5 2 Double Acting Cylinder

Figure 2.34: Double Acting Cylinder

The construction principle of a double-acting cylinder is similar to that of the

single-acting cylinder. However, there is no return spring, and the two ports are used
alternatively as supply and exhaust ports.

The double- acting cylinder has the advantage that the cylinder is able to carry out
work in both directions of motion. Thus, installation possibilities are universal. The force
transferred by the piston rod is somewhat greater for the forward stroke than for the
return stroke as the effective piston surface is reduced on the piston rod side by the cross-
sectional area of the piston rod.

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 Figure 2.35: Double-acting cylinder with end position cushioning

If large masses are moved by a cylinder, cushioning is used in the end positions to
prevent sudden damaging impacts. Before reaching the end position, a cushioning piston
interrupts the direct flow path of the air to the outside. Instead a very small and often
adjustable exhaust aperture is open.

For the last part of the stroke the cylinder speed is progressively reduced. If the
passage adjustment is too small, the cylinder may not reach the end position due to the
blockage of air.

With very large forces and high accelerations extra measures must be taken such
as external shock absorbers to assist the load deceleration. To achieve correct
deceleration:

 the regulating screw should first be screwed in fully and

 backed off in order to allow the adjustment to be increased slowly to the
optimum value.

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 2.5 3 Motors

Devices which transform pneumatic energy into mechanical rotary movement with
the possibility of continuous motion are known as pneumatic motors. The pneumatic
motor with unlimited angle of rotation has become one of the most widely used working
elements operating on compressed air. Pneumatic motors are categorized according to
design:

 Piston motors
 Sliding-vane motors
 Gear motors
 Turbines (high flow)

Figure 2.36: Air Motor

2.5 4 Rotary Actuators

The compact rotary actuator is suited to robotics and materials handling

applications where there is limited space. Rotary actuators are divided into continuous
motion and limited angle of rotation. The air motor is normally a high speed device with
either fixed or adjustable speed control.

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 Units with limited angle of rotation are fixed or adjustable in angular
displacement. The rotary actuator may be cushioned depending upon the load and speed
of operation.

Figure 2.37: Rotary Motion

2.6 Pneumatic symbols

The development of pneumatic systems is assisted by a uniform approach to the

representation of the elements and the circuits. The symbols used for the individual elements
must display the following characteristics:

 Actuation and return actuation methods

 Number of connections (all labeled for identification)
 Number of switching positions
 General operating principle
 Simplified representation of the flow path

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 The technical construction of the component is not taken into account in the abstract
symbol form. The symbols used in pneumatics are detailed in the standard DIN ISO 1219,
"Circuit symbols for fluidic equipment and systems".

2.6 1 Air supply and generation

The symbols for the energy supply system can be represented as individual
elements or as combined elements. If a standard and common air supply is used for all
components, then the simplified symbols can be used.

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 Figure 2.38: Symbols used in energy conversion and preparation

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 2.6 2 Directional control valves

In general, the symbols are similar for pneumatics and hydraulics but each control
medium has specific characteristics that are unique.

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 Figure 2.39: Directional control valves - symbol development.

The directional control valve is represented by the number of controlled

connections, the number of positions and the flow path. In order to avoid faulty
connections, all the inputs and outputs of a valve are identified.

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 Fig. 2.40: Directional control valves: ports and positions (ways)

A numbering system is used to designate directional control valves and is in

accordance with DIN ISO 5599-3. Prior to this a lettering system was utilized and both
systems of designation are presented here:

a) Working Lines

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 Port or Connection ISO 5599-3 Lettering System

Pressure port 1 P

Working line (signal output) 2,4 A,B

Exhaust port (3/2 way valve) 3 R

Exhaust port (5/2 way valve) 3,5 R,S

b) Pilot Lines

Port or Connection ISO 5599-3 Lettering System

Pilot line opens flow 1 to 2

Z
12
(Applied signal connects port 1 to
(single pilot 3/2 way)
port 2)

Pilot line opens flow 1 to 2

Y
12
(Applied signal connects port 1 to
(5/2 way valve)
port 2)

Pilot line opens flow 1 to 4

Z
(Applied signal connects port 1 to
14
(5/2 way valve)
port 4)

Pilot line flow closed

Z
10
(Applied signal inhibits flow from
port 1 to port 2)

Auxiliary pilot air 81, 91 Pz

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 Figure 2.41: Examples of designations

The methods of actuation of pneumatic directional control valves are dependent

upon the requirements of the task. The types of actuation vary;

 manually actuated
 mechanically actuated
 pneumatically actuated
 electrical and
 combined actuation.

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 Figure 2.42: Methods of actuation

2.6 3 Non-return valves

The non-return valve (check valve) is the basis for the development of many
combined components. There are two main configurations for non-return valves, with and
without the spring return. In order to release flow, the pressure force on the spring return
design must be greater than the spring force.

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 Figure 2.43: Non-Return Valve

2.6 1 Flow control valves

Most flow control valves are adjustable and permit flow control in both directions.
The arrow shows that the component is adjustable but does not refer to the direction of
flow; it is diagrammatic only.

In the case of the one-way flow control valve, a non-return valve is switched in
parallel with the flow control valve. Flow control is affected in one direction only.

Figure 2.44: Flow control valves

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 2.6 4 Pressure regulating control valves

The function of pressure valves, is to influence the pressure in an overall

pneumatic system or in a part of the system. Pressure regulating valves are generally
adjustable against spring compression. The symbols are distinguished according to the
following types:

 Pressure regulating valve without relief port

 Pressure regulating valve with relief port
 Pressure sequence valves

Figure 2.45: Pressure Valve

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 The symbols represent the pressure valve as a single position valve with a flow
path that is either open or closed initially. In the case of the pressure regulator the flow is
always open, whereas the pressure sequence valve is closed until the pressure reaches
the limit value as set on the adjustable spring.

2.6 5 Linear actuators

The linear actuators or cylinders are described by their type of construction and
method of operation. The single-acting cylinder, the double-acting cylinder and the
rodless cylinder form the basis for design variations.

The use of cushioning to reduce loads on the end caps and mountings during
deceleration of the piston is important for long-life and smooth operation. The cushioning
piston is shown on the exhaust air side of the piston. The arrow indicates adjustable
cushioning and not the direction of cushioned motion.

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 Figure 2.46: Several of Linear Actuator

2.6 6 Rotary actuators

Rotary actuators are divided into continuous motion and limited angle of rotation.
The air motor is normally a high speed device with either fixed or adjustable speed
control.

Units with limited angle of rotation are fixed or adjustable in angular

displacement. The rotary actuator may be cushioned depending upon the load and speed
of operation.

Figure 2.47: Rotary actuators

2.6 1 Auxiliary symbols

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 There are a number of important symbols for accessories which are utilized in
conjunction with pneumatics. These include the exhaust air symbols, visual indicators
and the methods of connection of components.

Figure 2.48: Auxiliary symbols

EXERCISE

1. List down six components in pneumatic system configuration.

2. Draw the diagram to show the pneumatic system structure and signal flow.
3. What are the primary levels in a pneumatic system?
4. Give five aspects should be considered in the preparation of the service air.
5. What is the maximum operating pressure of pneumatic components?
6. Name three components in the air supply unit and describe their functions
respectively.
7. List down five categories of valves.
8. Differentiate between spool and poppet valve.
9. List four valve operation methods.
10. Give three types of directional control valves.
11. What is the function of directional control valves?

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 12. What is the function of non-return valve?
13. List two types of non-return valves and explain their functions.
14. What is the function of flow control valve?
15. Explain the working principle of one way flow control valve.
16. What are the three main group of pressure control valve and explain the working
principles of each of them.
17. Describe the working principle of time delay valve.
18. Explain the working principle of two pressure valve and shuttle valve.
19. What are the typical examples of actuator categorized under linear and rotary motion?
20. Describe the working principle of single acting and double acting cylinder.
21. What is the different between air motor and rotary actuator?

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 CHAPTER 3

PNEUMATIC CIRCUIT DIAGRAM

Learning Objectives

At the end of the topic, trainees will be able to:

1. Construct the circuit diagram to control of a single acting cylinder

2. Develop the circuit diagram in order to control a double acting cylinder
3. Implement two pressure valve and shuttle valve in the pneumatic circuit diagram.
4. Construct the memory circuit diagram.
5. Draw the circuit diagram to control speed of the cylinder.
6. Apply quick exhaust valve in the circuit diagram.
7. Develop the pressure dependent control circuit.
8. Construct the circuit diagram with time delay valve.
9. Able to explain the working principles of the above circuit diagrams

References

1. D. Merkle, Hydraulics, bacis level, Festo, 1997

2. P. Croser, Pneumatics, basic level, Festo, 2003

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Chapter 3 Pneumatic Circuit Diagram

3.1 Direct and Indirect Control of a Cylinder.

3.1 1 Direct control of cylinder

The simplest level of control for the single or double acting cylinder involves direct
control signals. Direct control is used where the flow rate required to operate the cylinder
is relatively small, and the size of the control valve is also small with low actuating forces.
If the valve is 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"

Example 1: Direct control of a single-acting cylinder

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 Figure 3.1: Circuit diagram for direct control of a single acting cylinder

When the pushbutton is pressed, the air passes through the valve from 1(P) to the
2(A) port and extends the piston rod against the force of the cylinder return spring. When
the pushbutton is released, the valve spring returns the 3/2 way valve to its initial
position and the cylinder retracts. The air returns from the cylinder via the exhaust 3(R)
port.Since the cylinder is the only working element or actuator in the circuit, it is
designated 1.0. The final control element that extends the cylinder is designated 1.1.

Example 2: Direct control of a double acting cylinder.

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 Figure 3.2: Circuit diagram for direct control of a double acting.

If the pushbutton is pressed for a very short period, the cylinder only partially
extends and then retracts, since the spring resets the control valve as soon as the
pushbutton is released. The cylinder and valve will return to their initial position.
Therefore with this circuit, it is possible that the cylinder never reaches full extension. To
try and achieve full extension in this case, the pushbutton must be held down until the
cylinder moves fully forward.

3.1 2 Indirect Control of a Cylinder.

For controlling cylinders at high speed or of large diameter, the air flow required
determines whether a large size control valve should be used. The operating force to
actuate the valve may be relatively large and in this case indirect control is preferable.
A similar situation exists when a cylinder operates at high speed, and requires a
large valve that cannot be directly operated. The control element will have a large orifice
size and flow rate and be operated by pilot air to assist opening against the switching
force. This is indirect control.

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 Example 1: Indirect control of a single acting cylinder.

Figure 3.3: Circuit diagram for indirect control of a single acting cylinder

In the initial position, the single acting cylinder is retracted and the control valve
1.1 is in the un-actuated position, due to the spring return. The pushbutton valve is in the
spring return position with the connection at 2(A) exhausted to atmosphere. Therefore
the only active lines are the 1(P) lines of the two 3/2 way valves.
The 3/2 way pushbutton valve (1.2) opens the 1(P) air supply to the 2(A) port and
generates a signal at the 12(Z) pilot port of the control valve. The control valve 1.1 is
actuated against spring force and the 1(P) line is opened to the 2(A) port, causing the
single acting cylinder to extend.

The signal at the 12(Z) line remains as long as the pushbutton is held down, and
therefore the cylinder remains extended until the pushbutton is released. This is an
indirect pushbutton control of the cylinder.
If the pushbutton is released, the spring return closes the 1(P) port of the 3/2 way
valve and exhausts the 2(A) line to atmosphere. This removes the actuating pilot signal at

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 the control valve. The control valve is returned to the initial position by the return spring
and the single acting cylinder line is exhausted to atmosphere. The spring in the cylinder
retracts the cylinder to the initial position.

Example 2: Indirect control of a double acting cylinder

Figure 3.4: Circuit diagram for indirect control of a double acting cylinder.

After actuating the valve 1.2, it supplies a pilot signal to the 14(Z) port of the
control valve 1.1. This generates a signal at the outlet 4(A) and the cylinder extends until
the pushbutton is released. If the pushbutton is released the return signal is supplied
from the 2(B) port of valve 1.1 and the air is vented from the unpressurised side of the
cylinder via valve 1.1 exhaust port 5(R).
If the pushbutton is released before the cylinder fully extends, the cylinder
immediately returns to the initial position. Even though indirect control is used, the final
control element is a single pilot valve requires a sustained signal for it to remain operated.

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 Once the pushbutton is released, this pilot signal is exhausted through the 3/2 way valve
exhaust port 3(R) and the cylinder retracts.

3.2 Logic Functions: AND, OR.

The pneumatic shuttle valve and the two pressure valve have logic functions. The shuttle
valve has the characteristic of an OR function, whereby at least either of two inputs X and Y are
required to generate an output at port A of the valve. In the case of the two pressure valve, the
characteristic is that of the AND function, whereby both inputs X and Y are required to initiate
an output A.
The two pressure valve and the shuttle valve normally control the input signals' passage to
ensure special conditions are met in a circuit. For example, interlocks, safety measures and
operating conditions which are required prior to the actuation of a cylinder. The logic elements
have processor roles in a circuit, whereby signals are processed to meet the special conditions.

Example 1: The logic AND function: the two pressure valve.

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 Figure 3.5: Circuit diagram.

The two pressure valve is connected to the junction between the two 3/2 way pushbutton
valves. Upon operation of one of the pushbuttons, a signal is generated at the X or Y side
of the two pressure valve.
This signal is blocked by the two pressure valve. If the second pushbutton is also
operated, then the two pressure valve will produce a signal at port A which operates the
control valve 14(Z) pilot signal against the spring return and the cylinder extends.

The control valve can be a 4/2 way or 5/2 way valve. If either of the two signals produced
via the pushbutton valves is removed, then the two pressure valve will relieve the 14(Z) signal
back through the exhaust port of the non-operated 3/2 way valve.
The spring in the control valve switches the 5/2 way valve to the initial position. The
outlet 2(B) is active with the outlet 4(A) exhausted to atmosphere and the cylinder retracts.

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Example 2: The logic OR function: the shuttle valve.

Figure 3.6: Circuit diagram

The shuttle valve is connected to the junction between the two 3/2 way pushbutton
valves. Upon operation of one of the pushbutton, a signal is generated at the X or Y side of the
shuttle valve. This signal passes through the shuttle valve and is emitted at port A. This
reverses the control valve via pilot port 14(Z), and the cylinder extends.
The control valve can be a 4/2 way or a 5/2 way valve. If both of the signals produced via
the pushbutton valves are removed, then the shuttle valve will release the 14(Z) pilot signal
back through the exhaust port of one of the 3/2 way valves.
The return spring in the control valve switches the 5/2 way valve to the initial position.
The outlet 2(B) is active with the outlet 4(A) exhausted to atmosphere, and the cylinder
retracts.

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3.3 Memory Circuit and Speed Control of a Cylinder.

Figure 3.7: Example of circuit diagram.

4/2 way or 5/2 way double pilot valves possess the required memory function. The valve
retains its last switched position until an opposing signal is received. For this reason signals
created by the pushbutton signaling devices can be of short duration.
Upon operation of pushbutton 1.2, a signal is generated at the 2(A) port and the pilot port
14(Z) of valve 1.1. The 5/2 way memory valve switches and the signal from port 4(A) fully
extends the cylinder 1.0. If the pushbutton valve 1.2 is released, the signal at 14(Z) is exhausted
at the 3(R) port of the pushbutton valve 1.2.
The valve 1.1 remains in the switched position until the pushbutton valve 1.3 is operated.
If the pushbutton valve 1.2 is released and therefore there is no signal at 14(Z) then the signal
generated by 1.3 will return the memory valve to its initial position and the cylinder retracts.

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The cylinder remains retracted until a new signal is generated at 14(Z) by the valve 1.2. 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 pushbuttons being
operated, then the memory valve will remain in the last position attained. The flow control
valves have been fitted to throttle the exhausting air in both directions of piston motion. The
supply air is transferred through the by-pass check valve of the flow control valves, giving
unrestricted supply to the cylinder.

3.4 Quick Exhaust Valve.

Figure 3.8: Example of circuit diagram to show the application of quick exhaust valve.

In the initial state, the cylinder is in retracted position. If both of the 3/2 way valves are
actuated, a signal is present at the output port A of the two pressure valve 1.6. This reserves

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the 5/2 way control valve. The cylinder extends with air being supplied via an unrestricted
passage through the one way flow control valve 1.01.
The actuator travels rapidly to its forward end position since the pressure space on the
piston rod side is rapidly exhausted through the quick exhaust valve. If both 3/2 way valves
remain actuated, the cylinder remains in the forward end position. If at least one of the two
pushbuttons is released, the actuator is no longer pressurized, since the control valve reverses
via the return spring.
The actuator travels to its initial position under conditions of restricted flow (valve1.01)
and therefore at a reduced speed.

3.5 Pressure Dependent Control.

Figure 3.9: Example of circuit diagram

The cylinder extends if the 5/2 way directional control valve 1.1 is switched via the 14(Z)
port by the operation of the pushbutton valve 1.2. The plastic components are embossed

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under pressure by the die until the preset pressure set on the sequence valve is achieved. The
pressure on the advancing side of the cylinder is fed from a junction to the limit valve 1.3 and
then in series to the sequence valve.
The signal port 12(Z) at the sequence valve acts against the preset compression of the
adjustable spring. If the limit valve 1.3 is operated due to full extension of the cylinder and the
preset value is reached, then the sequence valve opens from 1(P) to 2(A) and sends a pilot
signal to port 12(Y) of the control valve 1.1. If there is no signal at 14(Z), then the memory valve
switches and air is supplied from the 2(B) port to retract the cylinder.
At the same time the air in the 4(A) port is exhausted and the pilot signal at the sequence
valve is therefore relieved through the exhaust port of the limit valve. Therefore the sequence
valve cancels the output signal 2(A) and thus the pilot signal 12(Y). The cylinder retracts to the
initial position. The pilot signals at 14(Z) and 12(Y) need only to be very short pulses to effect
the position of the 5/2 way control valve.
If the pressure at the sequence valve pilot line not reaches the preset limit of the spring adjustment,
then the cylinder will remain extended. If the cylinder encounters an obstacle or obstruction to the die
movement during extension to the forward position, the

cylinder will not retract since the sequence valve is dependent upon the operation of
the limit valve 1.3.

3.6 Time Delay Valves

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 Figure 3.10: Example of the circuit diagram with application of the time delay valve

The start conditions for the extension of the double acting cylinder 1.0 are the
acknowledgment of the retracted position (roller limit valve 1.4) a delay of five seconds after
the end of cycle due to timer 1.6 and the operation of the start button valve 1.2. The output
signal A at the two pressure valve 1.8 pilots the 5/2 way memory valve at 14(Z). The signal 4(A)
extends the cylinder at a preset speed via the flow control valve 1.02 (exhaust throttling).
The limit switch 1.4 is deactivated and therefore even if the start button is still held down,
the signal at 14(Z) is exhausted by the removal of the limit switch signal, which resets the timer
1.6 until the cylinder has retracted again.The cylinder reaches the limit valve 1.3 and produces a
pilot for the time delay valve 1.5.
The time delay valve is normally closed and only opens port 2(A) if the preset time, as
determined by the adjustable throttle, is reached. The air reservoir in the time delay valve fills,
and a pressure is reached that is sufficient to operate the timer against the spring return. A
pilot signal is produced 6 seconds after the limit valve 1.3 is operated ant that signal is then sent

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to the 5/2 way valve port 12(Y). The 5/2 way valve switches to the initial position with 2(B)
active and 4(A) exhausted.
The air to the cylinder is supplied to the return side and the speed controlled by the valve
1.01. The roller limit 1.3 is deactivated and the pilot signal to the timer 1.5 is cutoff, thereby
removing the 12(Y) signal from the 5/2 way valve. The cylinder retracts to the limit valve 1.4. A
new start signal can only occur if the roller of valve 1.4 is active. The timer 1.6 activates after 5
seconds and the start button must be pressed for a new cycle to commence.

EXERCISE

1. Draw the circuit diagram to :-

(i) direct control of a single acting cylinder.
(ii) direct control of a double acting cylinder.
(iii) indirect control of a single acting cylinder.
(iv) indirect control of a double acting cylinder.
Put the designation of every individual element in the circuit diagram and explain the
operation of the circuit diagram respectively.

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 2. Construct the circuit diagram to show the application of:-
(i) two pressure valve.
(ii) shuttle valve.

Describe the operation of the above circuit diagrams.

3. Draw the example of the memory circuit diagram and explain the operation of the
circuit.
4. Construct the circuit diagram to control speed of the cylinder.
5. Give an example of circuit diagram which applying the quick exhaust valve and explain
the working principles of the circuit.
6. Draw the example of pressure dependent control circuit. And describe the operation of
the circuit.
7. Construct the circuit diagram with time delay valve and explain the working principles of
the circuit.

CHAPTER 4

SAFETY REGULATION IN PNEUMATIC SYSTEM

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Learning Objectives

At the end of the topic, trainees will be able to:

1. Understand the six safety rules to be followed when using pneumatic equipment.
2. Apply the six safety rules when dealing with pneumatics.
3. Identify machine and workplace safety hazards associated with pneumatic systems.
4. List safety rules associated with individual pneumatic components.

References

3. D. Merkle, Hydraulics, bacis level, Festo, 1997

4. P. Croser, Pneumatics, basic level, Festo, 2003

Chapter 4 Safety Regulation in Pneumatic System

4.1 General Rules

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 Although most pneumatic power systems operate at low pressures of 100 psi / 690 kPa or
less, special care must be taken to prevent injury or damage. Safety rules must be
followed for your protection and those around you. Memorize and apply the following safety
rules anytime you are working with or around pneumatic power systems.

4.1 1 Do not point compressed air at eyes, ears, mouth, nose or skin.
This include blocking a compressed air line or fitting with fingers or hands as
shown in figure 4.1.

Figure 4.1: Handling compressed air.

4.1 2 Properly secure a hose or device that contains compressed air.

Fitting can be blown out. Mechanically test or pull connections before pressurizing.
Tie or hold down open, loose lines to avoid whipping when connecting into live pressure
lines. Every force has an equal and opposite reaction.
Think of all the rubber balloons that got away accidentally or on purpose after you
inflated them. The industrial plant equivalent of that is the industrial air hose that is open
but not tied down. With a metal fitting on the end of it, the sudden application of air
pressure can turn it into a dangerously whipping snake, as shown in figure 8.2, and
very likely hurt someone or damage something.

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 Figure 4.2: Unrestricted balloon and air line with air flowing

Always turn off the air pressure before connecting equipment and gradually turn
up the pressure where possible while observing for loose lines. Use strong enough holding
materials to assure they will hold under pressure.

4.1 3 Use proper equipment and pressures when cleaning with air.
Do not use air lines at full pressure to blow and clean. Reduce to 30 psi or below.
Use safety glasses. Safety glasses with side shields, as show in Figure 3, should be used
when cleaning or working with compressed air that can be released, although they are not
absolute protection.

Figure 4.3: Safety glasses used when cleaning

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 Use only OSHA approved blowguns. Around industrial plants, compressed air is
used to blow dirt, chips or waste to clean equipment, work areas or hard to get to areas,
and it is an ideal way of quickly doing the cleanup job. You will find it hardly too.
However, only certain kinds of blowers, as shown in figure 8.4, should be used
which reduce pressures to safer levels.

Figure 8.4: OSHA approved blowers

4.1 4 Use strong enough containers to safely hold compressed air.

Use only approved pressure-rated containers for compressed air storage. Discard
old and worn pressure lines and replace. Replace crazed parts before using. Crazing is the
development of tiny cracks caused by certain kinds of cleaning fluids (solvents). Use bowl
guards on air preparation equipment designed for everyday plant production use where
chemical cleaning, solvent aerosols, or compressor lubricants are uncontrolled.

4.1 5 Avoid continuous noise exposure.

The noise caused by the exhaust of a pneumatic component can be damaging to
the ears at certain levels or at least annoying.

4.1 6 Avoid actuator injury.

 Always mount the actuator securely.
 Use guards wherever possible.
 Tie down or securely clamp the work piece.

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  Keep your hands, face, feet, hair and clothing away from the actuator

4.2 Common hazards and remedies

Industrial uses of pneumatic power:
- produce linear motion.
- handle materials.
- operate portable hand tools.
- clean parts.
- safety hazards associated with each of these applications.

Actuators:
- produce large forces and move loads at high speed.
- actuator motion depends on properly working control valves.

Control valves:
- small valve malfunction can produce dangerous actuator motion.

Guards:
- minimize safety hazards near actuators.

Safety circuits:
- require both hands of operator to start actuator operation.
- are designed to keep operator’s hand away from moving parts.

Emergency stops:
- stop actuator operation immediately when pressed.
- must easy to reach and easy to actuate and able to respond immediately.

Lifts and hoists:

- make sure weight of object is within capacity of lift or hoist.
- never exceed recommended weight limit.
- never stand under a load.

4.3 Working with air tools

Air tools:
- usually do not have guards.

Air tools hoses:

- should be suspended from overhead position (if possible).
- should not run along floor.

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 Hazard of air tool hoses:
- sudden release of air from cut hose can cause hose to whip around.
- should comfortably reach work piece.
- should not be used to support tool.

Using compressed air for cleaning:

- never use air directly from air hose.
- always use appropriate nozzle.
- always wear safety glasses.

- avoid using air for cleaning where particles could damage other equipment.
- never use compressed air to clean particles from clothing.

4.4 Oil and water

Air exhaust:
- can be safety hazard.
- oil concentration levels in air can reach dangerous levels.
- work areas should be well ventilated.

Muffler reclassifies:
- reduce level of oil in exhausted air.
- decrease noise of exiting air and trap the oil.

Water in the system:

- corrodes component parts, causing them to become brittle.
- adds damaging contaminants to compressed air.

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 APPENDIX

PROBLEM SOLVING AND DISCUSSION

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Problem Solving and Discussion

Draw the pneumatic circuit diagrams to solve the following problems

Problem 1: Bending Device.

Sheet metals are to be U-formed using a single acting cylinder. The start signal is to be
given using a pushbutton.

Method:
a. Direct actuation (Direct control).
b. Indirect actuation (Indirect control).

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 Bending Device

Problem 2: Separating Product from a Magazine.

a. The piston is to extend when a pushbutton is pressed and return immediately to it start
position when the pushbutton is released. (Continuous actuation)

b. The piston is to extend when a pushbutton is pressed and return automatically to its
start position after reaching full extension. (Impulse actuation)

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 Separating Product from a Magazine

Problem 3: Automatic Washing Machine.

A container is to be moved up and down in the cleaning bath. The “start” and “stop”
signals for this continuous cycle are to be given by a push-button. The effect of the “stop” signal
must be that the container stops in the raised position.

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 Automatic Washing Machine

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