ELECTRO PNEUMATICS

Introduction to
Electro-
pneumatics

1
Air Compressors, Air Treatment and
Pressure Regulation

2
 Introduction

Main Components in Compressed

Electrical Equipment/

Air Systems
Compressors

• Intake air filters

• Inter-stage coolers
• After coolers
• Air dryers
• Moisture drain traps
• Receivers
© UNEP32006
 Air Compressors

COMPRESSOR – A device which takes a definite quantity of fluid ( usually gas, and

most often air ) and deliver it at a required pressure.

Air Compressor – 1) Takes in atmospheric air,

2) Compresses it, and

3) Delivers it to a storage vessel ( i.e. Reservoir ).

Compression requires Work to be done on the gas,

 Compressor must be driven by some sort of Prime Mover ( i.e. Engine )

 Classification
Air Compressors

Reciprocating Rotary

Centrifugal

No. of Stages No. of Sides of Piston

for Compression in operation
Single – stage Single – acting
Multi - stage Double - Acting
 Training Agenda: Compressor

Introduction
Electrical Equipment/

Types of compressors
Compressors

© UNEP62006
 Types of Compressors

Two Basic Compressor Types

Electrical Equipment/
Compressors

Type of
compressor

Positive
Dynamic
displacement

Rotary Centrifugal Axial

Reciprocating
© UNEP72006
 Types of Compressors

Reciprocating Compressor
Electrical Equipment/

• Used for air and refrigerant compression

• Works like a bicycle pump: cylinder volume reduces
Compressors

while pressure increases, with pulsating output

• Many configurations available
• Single acting when using one side of the piston, and
double acting when using both sides

(King, Julie)
© UNEP82006
 Types of Compressors

Rotary Compressor
Electrical Equipment/

• Rotors instead of pistons: continuous

discharge
Compressors

• Benefits: low cost, compact, low weight,

easy to maintain
• Sizes between 30 – 200 hp
• Types
• Lobe compressor
• Screw compressor
• Rotary vane / Slide vane Screw compressor
© UNEP92006
 Types of Compressors

Centrifugal Compressor
Electrical Equipment/

• Rotating impeller
Compressors

transfers energy
to move air
• Continuous duty

• Designed oil
free
• High volume
applications
> 12,000 cfm
(King, Julie) 10
© UNEP 2006
Air Receivers And Compressor Control

11
Stages of Air Treatment

12
 Stages of Air Treatment

Air dryers
Before air can be used, this
excess moisture has to be
removed to bring air
humidity and dew point to A typical water trap
reasonable levels. and separator.

13
 Pressure Regulation

Relief Valves - The simplest pressure-regulating device normally

used to control pressure but is employed as a back up device
should the main pressure control device fail. They are
commonly fit ted, for example, to air receivers.

14
Non-relieving pressure regulators

15
Relieving pressure regulators

16
Introduction to electro-pneumatics

 Electro-pneumatic is widely used in many areas of industrial

automation, production, assembly, and packaging systems

worldwide. These systems are driven by electro-pneumatic control

systems. The following figures show different applications of electro-

pneumatic machines.

17
different applications of electro-pneumatic machines

Ship's Anti heeling system

18
different applications of electro-pneumatic machines

Bilge System

19
Introduction to electro-pneumatics

 In electro-pneumatics, the pneumatic components are controlled by

using electrical and electronic circuits. Electronic and electromagnetic

sensors, electrical switches and industrial computers are used to

replace the manual control of a pneumatic system.

20
Signal flow in electro-pneumatic control system

Command execution

Signal output

Signal processing

Signal Input
Next
21
Signal flow in electro-pneumatic control system

24
Advantages of electro-pneumatic systems:

1- Greater reliability:

Less moving parts subjected to wear compared to mechanical control

systems.

2- Reduced installation complexity:

Less components and hoses, leads to less effort in planning and

commissioning especially with large and complex systems.

25
Advantages of electro-pneumatic systems:

3- The control system can be easily modified and adapted:

It is easier to change wiring and modify programs rather than changing

mechanical components and hose networks.

Example: the AND gate is replaced with logic and through using

electrical switches.

26
Advantages of electro-pneumatic systems:

4- Easy handling: Less complexity

5- Secure mounting: Fewer hoses

6- Environmentally-friendly coupling system: Less lubrication require

27
Components of electro-pneumatic system

 The electro pneumatic system is normally consists of the following

items:

1. DC power supply

2. Switches

3. Relays

4. Solenoid valves

5. Sensors
28
DC power supply

 The power supply is used to reduce and convert the 230 V AC to a

24 V DC.

29
DC power supply
 The power supply components which are shown below have the

following functions:

30
The transformer
 The transformer reduces the main voltage (230 to 24 volt).

31
The rectifier
 The rectifier converts the AC voltage to DC voltage.

32
The stabilizer
 The stabilizer is used to smooth and maintain constant voltage at

the output.

33
 Switches
 Switches are installed in an electric circuit to connect or interrupt the

electric current.

 These switches are divided into:

1. Control switches: keep the selected position such as detent switches.

2. Push button switches: maintain the selected position as long as the

switch is activated.

34
 Switches
 In this module, three types of switches will be discussed:

Push button Detent

switches switches

Limit
switches

35
Push button switches
 These switches are activated manually and used to connect or

disconnect the electric current in the control circuit. There are three

types of the push button switches:

Normally Normally closed Changeover

opened contact contact contact
(make) (break) (two-way)

36
Push button switches
 • A push button is a switch used to close or open an
electric control circuit. • They are primarily used for
starting and stopping of operation of machinery. • This
causes set of contacts to open or close. Push buttons
are of two types
i) Momentary push button
ii)Maintained contact or detent push button

37
Push button switches
• Momentary push buttons return to their unactuated
position when they are released.
• Maintained (or mechanically latched) push buttons
has a latching mechanism to hold it in the selected
position. • The contact of the push buttons,
distinguished according to their functions,
• i) Normally open (NO) type
• ii) Normally closed (NC) type
• iii) Change over (CO) type.

38
Normally opened contact (make)
 In the case of a normally opened switch, the circuit is open if the
switch is in its initial position.

 Pressing the pushbutton results in closing the circuit and then the

current will flow to load. When the plunger is released the spring will
returns the switch to its initial position.

39
Normally open (NO) type
• In the NO type, the contacts are open in the normal
position, inhibiting the energy flow through them. •
But in the actuated position, the contacts are closed,

40
Normally closed contact (break)
 In the case of the normally closed switch, the circuit is closed when

the switch is in its initial position. The circuit is interrupted by pressing

the pushbutton. The figure shows the ISO symbol of the push button

N/C.

41
Normally closed (NC) type
In the NC type, the contacts are closed in the normal
position, permitting the energy flow through them. •
And, the contacts are open in the actuated position,
inhibiting the energy flow through them.

42
Changeover contact (two-way)

The changeover contact, shown below combines the function of the

normally open and normally closed. Changeover contacts are used to

close one circuit and open another circuit in one switching operation.

2 4

43
Changeover contact
A changeover contact is a combination of NO and NC
contacts.

44
Detent switches
 These switches keep the selected position; the switch position

remains unchanged until a new switch position is selected. It is called

detent switch or a latching switch.

45
Detent switches

 The figures below show the ISO symbol of the normally open detent

switch and normally closed detent switch respectively.

 Detent switches also designed to be as normally open, normally

closed or changeover switches.

46
Limit switches
 The limit switch (shown below) is actuated when a machine part or

a work-piece is in a certain position. Normally, actuation is affected by

a cam or cylinder piston.

47
Limit switches
 Limit switches are normally changeover contacts and can be

connected according to the required control circuit. The limit switch can

be used in circuit according to one of the following:

 Normally open switch

 Normally closed switch

 Changeover switch

48
 Relays
 A relay is defined as an electromagnetically actuated switch.

 When the voltage is applied to a solenoid coil terminals (A1, A2) in

Figure below, it will become an electromagnet which in turn attracts the

contacts of the relay either closing or opening them.

 The spring returns the contacts to the initial position immediately

after disconnecting the voltage at the coil terminals.

49
When a voltage is applied to the solenoid coil, an
electromagnet field results.
• This causes the armature to be attracted to the coil core.
• The armature actuates the relay contacts, either closing or
opening them, depending on the design.
 • A return spring returns the armature to its initial
position when the current to the coil is interrupted.

50
 Electrically actuated
directional control valves -
Solenoid valves

51
Introduction
 Two forms of energies are used to operate any electro-pneumatic

control system:

 Electrical energy

 Compressed air energy

52
Introduction
 Electrically actuated directional control valves (DCVs) are switched

with the aid of an electric coil that is called a solenoid. The electric coil

attracts or repels the valve spool as shown below:

53
Introduction
 When the pushbutton switch is pressed (activated), an electric

current flows through the solenoid coil, the solenoid is energized

causing the valve spool to move, which in turn will switch the valve to

the second position where the air flows to move the cylinder piston

forward as illustrated in the following figure:

54
Introduction
 Releasing the pushbutton terminates the current flow, which in turn

de-energizes the solenoid and the DCV moves back to its normal

position.

55
Types of solenoid valves

 There are two types of solenoid valves used in electro-pneumatic

systems:

Single solenoid valve

with a spring return Double solenoid valves.
(reset)

56
Single solenoid valve with a spring return (reset)

 The valve remains in the actuated position as long as the current

flows through the solenoid.

57
Single solenoid valve with a spring return (reset)

 Example: 5/2 DCV with single solenoid and spring return:

58
Double solenoid valves
 The valve will keep and maintain the last switched position even

when no current flows through the solenoid. It is sometimes called

memory valve.

59
Double solenoid valves
 Example: 5/2 DCV, with double solenoid:

60
Control in electro-
pneumatics

61
Control in electro-pneumatics

 There are two general ways to control the electro-pneumatic systems:

Direct Control Indirect

Control

62
Direct control in electro-pneumatics

 Direct control is the control of an

electro-pneumatic valve without using

intermediate components such as a relay,

a contactor or an industrial computer

(PLC). The valve is connected directly to

electric switch as shown in the figure:

63
Electro pneumatics circuits for
single actuator
Forward stroke: The circuit is
closed when push button PB
closes. A magnetic field is
produced in the coil Y. The
armature in the coil opens the
passage for the compressed
air. The compressed air flows
from 1 to 2 of the 3/2 DCV to
cylinder, which travels to the
final forward position.

64
Electro pneumatics circuits for
single actuator
Return stroke: When the push
button PB is released, the
circuit is interrupted. The
magnetic field at coil Y
collapses, the 3/2 way valve
switches back to its original
position as shown in Figure
1.27. The compressed air in the
cylinder then exhausts
through port 3 of the DCV and
the cylinder travel to the final
rear position. 65
Indirect control in electro pneumatics
 Indirect control is the control of an electro-pneumatic valve using

intermediate components such as relays, contactors or programmable

logic controllers (PLC).

66
Indirect Control of single acting cylinder
 Forward stroke: The circuit is
closed when push button PB
closes. Closing of Push
button PB energises a relay
K1. The coil Y is energised via
normally open contact K1
(indirect energising). A
magnetic field is produced in
armature of the coil Y opens
the passage for the
compressed air. The
compressed air flows from 1 to
2 of the 3/2 DCV to cylinder,
which travels to the final
forward position.

67
Indirect Control of single acting cylinder
 Return stroke: When the
push button PB is released,
the circuit is interrupted.
Opening of Push button PB
de-energises a relay K1. The
magnetic field at coil Y is
collapses due to the opening
of contact K1 the 3/2 way
valve switches back to its
original position as shown in
Figure 1.28. The compressed
air in the cylinder then
exhausts through port 3 of
the DCV and the cylinder
travel to the final rear
position.

68
Presentation of Ship's Electro-
Pneumatics Sample Electrical
Diagram , Wiring Diagram
Discussion

69
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