This document discusses low cost automation using pneumatic systems. It begins with an overview of automation and pneumatics, explaining that pneumatics can provide low cost automation solutions through reducing labor costs, machine investment costs, and increasing productivity. The document then covers various pneumatic components and applications, advantages and disadvantages of pneumatics, pneumatic standards, classifications of pneumatic elements, and examples of pneumatic circuits.
This document discusses different types of actuation systems used in control systems, focusing on pneumatic and hydraulic systems. It describes how directional control valves are used to direct fluid flow through pneumatic and hydraulic systems. Common types of directional control valves include spool valves, rotary spool valves, and poppet valves. Process control valves are also discussed, along with how diaphragm actuators are used to control fluid flow rates. Finally, the document briefly covers single-acting and double-acting cylinders used in pneumatic and hydraulic systems.
application of Direction control valve in automatic transmissionZIYAD AMBALANGADAN
This document discusses directional control valves and their application in automatic transmissions. It begins by defining directional control valves as valves used to control the direction of fluid flow in hydraulic circuits. It then classifies valves based on their construction, number of ports, switching positions, and actuation mechanism. Examples of poppet and spool valves are described. Applications of directional control valves in automatic transmissions include using them to direct fluid flow to engage or disengage clutches based on vehicle speed. In conclusion, directional control valves are used to distribute hydraulic energy and control the start, stop, and direction of pressurized fluid flow.
This document discusses pneumatic systems and their components. It covers the basics of pneumatic systems including common components like compressors, filters, dryers, receivers, control valves and actuators. It also discusses the gases used, advantages and disadvantages of pneumatic systems, applications, electro-pneumatic controllers and system diagrams. Hydraulic systems are mentioned but not described in detail.
Pneumatics: Shuttle, Twin pressure, Quick Exhaust, Time Delay, FRLAbhishek Patange
The document discusses various components used in pneumatic systems including logic gates, valves, and FRL units. It begins with explanations of shuttle valves and twin pressure/dual pressure valves that can function as OR and AND logic gates respectively. Various valves are then discussed such as time delay valves, quick exhaust valves, and their applications. Speed control methods and the stick-slip effect in pneumatics are also covered. Finally, the construction and working of the main components of an FRL (filter, regulator, lubricator) unit are explained in detail with diagrams.
The document discusses different types of hydraulic cylinders and rotary actuators. It describes single acting cylinders that work in one direction, double acting cylinders that work in both directions, and telescopic cylinders for large strokes or limited spaces. It also covers properties of cylinders, calculations, buckling checks, and cushioning cylinders at the end of strokes. Rotary actuators discussed include vane, piston, and limited angle types.
The document discusses pneumatic systems and components. It describes how pneumatic systems use compressed air to transmit power and operate cylinders, valves, and other components. Some key advantages of pneumatic systems mentioned include being fast, easily transportable, variable speed and pressure, and clean operating. Common applications described are industrial robots, machine tools, brakes on vehicles, and dental/medical tools. The document also provides details on various pneumatic components like cylinders, valves, connectors, and their functions.
Fluid power systems use pressurized liquids or gases to transmit power through hydraulic and pneumatic components. Hydraulic systems use liquids, most commonly mineral-based hydraulic oils. The document discusses the basic principles, components, and applications of hydraulic systems. It explains that hydraulic systems operate based on Pascal's law, where pressure applied anywhere in an incompressible fluid is transmitted equally throughout. Common components include pumps, valves, actuators, reservoirs, filters, hoses, and seals. Hydraulic systems are used in various industrial machinery and equipment due to advantages like power density and control capabilities.
The document discusses hydraulic symbols according to ISO 1219 standards, including symbols for hydraulic pumps and motors, actuators like cylinders, directional control valves, pressure control valves, flow control valves, check valves, and other accessories. It provides information on the functions of different hydraulic components like pumps converting mechanical to hydraulic energy, motors converting hydraulic to mechanical rotation, cylinders providing linear motion, and various valve types controlling direction, pressure, and flow within hydraulic circuits.
Hydraulic Valves and Hydraulic System AccessoriesRAHUL THAKER
Hydraulic Valves and Hydraulic System Accessories:
Direction control valves,Pressure control valves, Flow control valves, Non-return valves, Reservoirs,Accumulators, Heating & cooling devices, Hoses. Selection of valves for circuits.
In hydraulic and pneumatic systems flow control valves are necessary to vary the speed of actuator. Flow control valves are placed in between Actuator and Direction Control (DC) Valve
Hydraulic actuators convert hydraulic energy into mechanical motion and come in two types: linear actuators, which produce linear motion, and rotary actuators, which produce rotational motion. Linear actuators include single acting cylinders, double acting cylinders, and double rod cylinders. Rotary actuators include rotary vane actuators and rack and pinion actuators, which can be single or double cylinder designs.
Applied Hydraulics and Pneumatics - Unit-1- Fluid Power system and FundamentalsDr.S.SURESH
This document provides an overview of applied hydraulics and pneumatics. It discusses fluid power systems and their advantages over other transmission methods. The objectives are to understand fundamental principles and applications of hydraulic and pneumatic machines. Key topics covered include properties of hydraulic fluids, fluid power symbols, basics of hydraulics like Pascal's law and fluid flow, and losses in valves and fittings. Examples of industrial applications are also provided.
This document provides an overview of compressed air systems, including:
- The types of compressors and their characteristics such as reciprocating, rotary, centrifugal, and axial compressors.
- How compressors work using principles such as the ideal gas law and Bernoulli's equation.
- Factors that affect the energy consumption of compressed air systems such as inlet air conditions, pressure settings, piping layout and leaks.
- Methods for improving efficiency such as variable speed drives, capacity control, and detailed energy audits.
The document discusses compressed air systems in detail over 5 sections, covering the scope of work, types of compressors, selection criteria, performance comparisons, and system components.
This document discusses different types of hydraulic pressure control valves. It describes pressure relief valves, pilot operated relief valves, sequence control valves, and other types. Pressure relief valves limit pressure by diverting fluid to the reservoir when pressure reaches a set point. Pilot operated relief valves use a piston or spool controlled by a pilot valve. Sequence valves provide flow to a second actuator after the first reaches a threshold pressure. The document also provides examples of applications for different valve types.
The document discusses hydraulic systems and their components. It begins with an introduction to hydraulic systems and then describes the main components, including reservoirs, filters, control valves, pumps, accumulators, and actuators. It explains that reservoirs store hydraulic fluid and help remove contamination with features like baffle plates and air breathers. Filters, including suction strainers and pressure line filters, work to remove particles from the fluid and protect components. Control valves direct flow and pressure. Pumps and accumulators work with valves to power hydraulic circuits. Actuators, such as cylinders and motors, provide the mechanical output of hydraulic systems.
This document discusses different types of air compressors and components of compressed air systems. It describes the main types of compressors as positive displacement (reciprocating and rotary) and dynamic (centrifugal and axial). Reciprocating compressors use pistons to compress air in a pulsing manner, while rotary compressors use rotors for continuous compression. Centrifugal compressors use an impeller to transfer energy and compress large volumes of air continuously. The document also discusses assessing compressor efficiency using various metrics and identifies opportunities to improve energy efficiency such as reducing leaks, properly setting operating pressures, controlled usage, and implementing maintenance best practices.
Air compressor overview and basic selection guideAnilkumar B Nair
Provide an overview of Air compressors
Provide a generic guideline for Air compressor selection process
This presentation is prepared for target audience:Facility Managers, Utility Engineers. Technicians and Process associates
ppt on compressed air system and air trimmingSurajWalanju1
This document discusses compressed air systems and impeller trimming. It provides definitions of compressed air systems, impeller trimming, and the main components of compressed air systems. It also lists methods to improve the performance of compressed air systems, such as improving air intake quality, detecting and repairing air leaks, implementing variable speed drives, and recovering waste heat from compressed air.
The document discusses pneumatic calculations for an LSF PU Hall. It covers calculating key parameters like pressure, flow rate, temperature and air quality. Specific calculations covered include air production ratio, pressure drop, air purification percentage, air consumption, required pressure and temperature at different stages. The document also provides calculations for specific pneumatic components and their air consumption. It analyzes the current system and provides solutions to improve efficiency, such as installing an air dryer and active carbon filters. Maintaining data through regular analysis of air supply, quality, consumption and leak detection is recommended to optimize the system.
The document discusses air compressors and pneumatic systems. It describes how air compressors work by reducing the volume of air and increasing pressure using positive displacement or dynamic mechanisms. Common types of air compressors include reciprocating, rotary screw, and centrifugal compressors. Reciprocating compressors use pistons in cylinders to compress air in single or multiple stages to achieve higher pressures. Selection of an air compressor depends on required pressure, air flow rates, cylinder geometry and piston speed. Compressed air finds applications in powering pneumatic tools and equipment.
Pneumatics uses compressed air to transmit power in industrial applications. Some key points:
- Compressed air is clean, safe, and can be transported easily through piping systems. However, it requires good preparation to remove moisture and particles.
- A typical pneumatic system includes an air compressor, dryer, receiver tank, filters, regulators, and lubricators to prepare and distribute the compressed air.
- Pipelines are installed with downward slopes and outlets pointing up to prevent condensation buildup. Ring circuits allow bidirectional air flow for uniform supply.
- Common components are cylinders, motors, and valves to convert compressed air into motion, controlled by pneumatic circuits and processing elements like directional valves
An air compressor is a mechanical device that increases the pressure of air by reducing its volume. It uses either positive displacement or dynamic compression methods. Positive displacement compressors like reciprocating compressors increase pressure by reducing the air volume in an enclosed chamber. Reciprocating compressors are commonly used in pneumatic applications. They consist of pistons moving inside cylinders to draw in, compress, and discharge air. Multi-stage compressors are needed to achieve higher pressures over 35 kg/cm^2. Selection of an air compressor depends on the required pressure, air flow rates, cylinder geometry, piston speed, and layout of the pneumatic system.
An air compressor is a mechanical device that increases the pressure of air by reducing its volume. It uses either positive displacement or dynamic compression methods. Positive displacement compressors like reciprocating compressors increase pressure by reducing the air volume in an enclosed chamber. Reciprocating compressors are commonly used in pneumatic applications. They consist of pistons moving inside cylinders to draw in, compress, and discharge air. Multi-stage compressors are needed to achieve higher pressures over 35 kg/cm^2. Proper selection of an air compressor depends on the required pressure, flow rates, cylinder geometry, piston speed, and layout of the pneumatic system.
chapter-no-3-air-compressors.ppt for electricbasant11731
An air compressor is a mechanical device that increases the pressure of air by reducing its volume. It is used in various pneumatic applications like powering tools, operating cranes and brakes, spraying in agriculture, and conveying materials. There are two main types - positive displacement compressors that reduce air volume in an enclosed chamber, and dynamic compressors that impart energy to air flowing through a rotor. Reciprocating compressors are commonly used positive displacement compressors that operate a piston inside a cylinder to compress air in one or multiple stages to higher pressures. Selection of an air compressor depends on the required pressure, air flow rates, cylinder geometry and size, and layout of the pneumatic system.
This document discusses air compressors and pneumatic systems. It describes how air compressors work by reducing the volume of air and increasing pressure using positive displacement or dynamic compression methods. Reciprocating air compressors are described as the most common type, using pistons in single or multiple stages to compress air. Other compressor types like rotary vane, centrifugal, and screw compressors are also summarized. Key factors for selecting a suitable air compressor like pressure, flow rates, cylinder geometry and layout are outlined.
Pneumatic systems use compressed air to achieve low-cost automation in industries. They are widely used by small and medium enterprises to reduce costs through decreasing machine investment, process time, and increasing productivity and quality consistency. Pneumatics offer simple and easy control through pneumatic components like cylinders, valves, and regulators. Common applications include pushing, pulling, lifting, feeding, clamping, and pressing operations in manufacturing assembly lines, packaging, bottling, vehicle cleaning, and more. While pneumatic systems are lighter and easier to control than hydraulics, they typically operate at lower pressures of 5-10 bar.
This document discusses compressed air systems and improving their efficiency. It describes the types of air compressors, including positive displacement and dynamic compressors. It outlines the key components of compressed air systems like filters, coolers, dryers and traps. It discusses improving efficiency through proper sizing, pressure settings, intake conditions and preventing leaks. The goal is to optimize compressor performance and minimize energy consumption.
What Is the Basic Working Principle of an Air Compressor_.pdfaliaseo052
The basic working principle of an air compressor revolves around converting power into potential energy stored as compressed air. This process involves drawing in ambient air, compressing it to a higher pressure, and then compressing it for various applications.
By understanding this fundamental mechanism, one can appreciate the versatility and efficiency of air compressors in numerous settings, from industrial manufacturing to everyday tools and devices.
An air compressor is a device designed to pressurize air, which can be used for various purposes, from inflating tyres to powering pneumatic tools.
What Is the Basic Working Principle of an Air Compressor.docxcemenntcompressor
The basic working principle of an air compressor revolves around converting power into potential energy stored as compressed air. This process involves drawing in ambient air, compressing it to a higher pressure, and then compressing it for various applications.
Compressed air Energy saving possibilities in textile millsAshok Sethuraman
The textile mills are aware now that in their total Electricity units consumed per day towards compressed air, they are losing more than 30 % units in compressed air. But, in the total Electricity units per day consumption, the mill can achieve only around 5 to 10 % reduction in that Units Per Day after the energy audit & implementation.
But here in compressed air, they find the Low Hanging Fruit with zero & low cost payback. Compressed air leakage is a hidden losses daily happening in the mill and if not identified and corrected today, this aggravates the losses, which are accelerating now.
When the mill goes for modernization, the automated production demands more compressed air usage. So instead of arresting the existing air leakages, now the mill buys more compressors so satisfy the production demands, but leakage increases more.
This document discusses hydraulic and pneumatic systems. It begins by defining the learning outcomes, which are to understand the working principles of hydraulic and pneumatic systems and know how machines using these systems operate. It then provides explanations of how hydraulic systems work using principles like Pascal's law. Examples of equipment that use hydraulic systems are given, such as hydraulic jacks, presses, forklifts, and brakes. The working principles of pneumatic systems are then covered, explaining how compressed air is used to perform tasks. Components of pneumatic systems and diagrams of system setups are presented. Advantages and disadvantages of both systems are listed. References for further information are provided at the end.
Air Compression and Electricity Generation by Using Speed Breaker with Rack A...IJMER
On roads, speed breakers provided to control the speed of traffic in rushed areas. The
potential energy in terms of weight of vehicle is loss on speed breaker can be utilized for useful
purposes. This paper describes the potential energy of such type of energy available on roads and its
utilization for useful work. The stages of development of a speed breaker device are described and the
mechanism to generate electricity using rack, pinion and speed increasing gear box and generator
and store compressed air with the help of piston cylinder compressor arrangement. Whenever the
vehicle is allowed to pass over the speed breaker dome, it gets pressed downwards. As the springs are
attached to the dome, they get compressed and the rack, which is attached to the bottom of the dome,
moves down in reciprocating motion. Since rack has teeth connected to pinion there is conversion of
reciprocating motion of rack in to rotary motion of pinion, but the two gears rotate in opposite
direction. So that shafts will rotate with certain RPM these shafts are connected through a belt drive
to the generators, which converts the mechanical energy into electrical energy. The rack is attached
to piston rod of cylinder so downward stroke of rack we can use for air compression in reservoir, with
help of piston cylinder arrangement. Simultaneously reciprocating piston cylinder arrangement
compresses the air and stores it in the reservoir. We can use the generated electricity and compressed
air for different purpose
The document summarizes the components and operation of a compressed air system and adsorption air dryer.
The compressed air system supplies instrument and plant air using four screw compressors, separate piping headers, pre-filters, instrument air dryers, after-filters, instrument air receivers, and controls including an emergency stop button and electronic regulator.
The adsorption air dryer removes moisture from compressed air using desiccant towers, heating one tower to regenerate the desiccant while the other tower dries the air in cycles. It has a long desiccant life through indirect heat contact and prevents drops in dew point through heated regeneration compared to heatless dryers.
The document summarizes the key components of a compressed air system and adsorption air dryer. The compressed air system supplies instrument and plant air using four screw compressors, separate piping headers, air filters, receivers, and dryers. It regulates air pressure and has safety features. The adsorption air dryer uses a desiccant to remove moisture from compressed air in cycles of drying, regeneration using heated air, and purging. It has components like towers, valves, heaters and instruments to control the process and ensure dry air output.
Abstract: The shearing machine and bending machine is most important in sheet metal industry. This machine should be used for straight cutting machine with wide application. But in some industry hand sheet cutter and hand bender are used. For that machine to operate the human effort are required. The machine should be simple to operate and easy to maintain, hence we tried out to develop the Pneumatic Shearing and Bending Machine.
In shearing operation as the punch descends upon the metal, the pressure exerted by the punch first cause the plastic deformation of the metal. Since the clearance between the punch and the die is very small, the plastic deformation takes place in a localized area and the metal adjacent to the cutting edges.
In bending operation the bend has been made with the help of punch which exerts large force on the work clamped on the die. The bending machine is designed in such a way that, it works automatically. The machine is designed by observing the factors to improve the efficiency and to reduce the cycle time by producing quality output. Automation of machine is achieved with the help of pneumatic system.
This paper involves the design of an efficient system which reduces the human effort and help to increase production output. It also includes pneumatic system, pneumatic component and shearing die and bending die.
General Air Products, Inc. - Air Compressor Selection and Design for Dry Pipe Fire Sprinkler Systems. This presentation is designed to educate fire sprinkler professionals, especially designers, engineers and technicians on the fundamentals of air compressor design, function and proper sizing and selection. For questions on this presentation please contact us at 800-345-8207 or visit our web site www.generalairproducts.com
I am Dr. T.D. Shashikala, an Associate Professor in the Electronics and Communication Engineering Department at University BDT College of Engineering, Davanagere, Karnataka. I have been teaching here since 1997. I prepared this manual for the VTU MTech course in Digital Communication and Networking, focusing on the Advanced Digital Signal Processing Lab (22LDN12). Based on, 1.Digital Signal Processing: Principles, Algorithms, and Applications by John G. Proakis and Dimitris G. Manolakis, Discrete-Time Signal Processing by Alan V. Oppenheim and Ronald W. Schafer, 3.Digital Signal Processing: A Practical Guide for Engineers and Scientists" by Steven W. Smith. 4.Understanding Digital Signal Processing by Richard G. Lyons. 5.Wavelet Transforms and Time-Frequency Signal Analysis" by Lokenath Debnath . 6. MathWorks (MATLAB) - MATLAB Documentation
Presentation slide on DESIGN AND FABRICATION OF MOBILE CONTROLLED DRAINAGE.pptxEr. Kushal Ghimire
To address increased waste dumping in drains, a low-cost drainage cleaning robot controlled via a mobile app is designed to reduce human intervention and improve automation. Connected via Bluetooth, the robot’s chain circulates, moving a mesh with a lifter to carry solid waste to a bin. This project aims to clear clogs, ensure free water flow, and transform society into a cleaner, healthier environment, reducing disease spread from direct sewage contact. It’s especially effective during heavy rains with high water and garbage flow.
Hate speech detection using machine learningrakeshrocking3
Hate speech detection involves the application of natural language processing (NLP) and machine learning techniques to identify and categorize text that contains harmful, offensive, or discriminatory language targeted towards individuals or groups based on attributes like race, religion, ethnicity, gender, or sexual orientation. The goal is to automate the process of identifying such content to prevent its spread and mitigate its negative impact.
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The Control of Relative Humidity & Moisture Content in The AirAshraf Ismail
To many of us Relative Humidity (RH%) & Moisture Content (g/ kg) are confusing terms & we often don't know which one of them to choose in order to highlight our "Humidity" issues!
This post is to briefly address the definition of Relative Humidity, Moisture Content , Moisture Load Sources & Humidity Control Hazard!
2. CONTENTS
About Automation
About Pneumatics
Applications
Advantages & Disadvantages
Pneumatic Standards
Classification of Pneumatic elements
Applications of air cylinders
Components of Pneumatics
Comparison between Pneumatic, Electro-pneumatic &
PLC based control system
Air pressure losses
Malfunctions of Pneumatic system
General safety measures
Basics Pneumatic circuits
3. •Automation is basically the delegation of human control
function to technical equipment for
•Increasing productivity
•Increasing quality
•Reducing cost
•Increasing safety in working condition.
What is Automation
9. In general, automation in industries are classified into
three categories.
Out of the above three, pneumatic systems are used in
achieving Low Cost Automation in industries,
1) To reduce labor cost,
2) To reduce machine investment cost
3) To increase productivity
4) To reduce human efforts
INDUSTRIAL AUTOMATION
Pneumatics Hydraulics
Electrical and
Electronics
10. In Greek “Pneuma” means air.
Study (or) subject deal with “Pneuma” / compressed air is
called as “Pneumatics”.
Products that use compressed air as medium for operation
are called as “Pneumatic components”.
What is Pneumatics ?
11. Mechanisms which
use air pressure to
apply mechanical
force and
displacement (work)
The pneumatic
devices we use are
basically binary
actuators – either
retracted or
extended
Retracted
Cylinder
Extended
Cylinder
What is Pneumatics ?
continued…
12. Pneumatics is widely used by SMEs for implementing
“Low Cost Automation”
1) To reduce machine investment cost
2) To reduce the process time
3) To increase productivity, and
4) To have consistent quality
Automation .mp4
Low Cost Automation
13. Advantages and Limitations of Pneumatics
Advantages
Simple
Easy to control
Can apply a lot of force from a small, light package
Force is limited by air pressure and cylinder diameter
The speeds and forces are infinitely variable
14. Advantages and Limitations of Pneumatics
continued…
Advantages
Pneumatic tools when over loaded will stop and so safe,
as compared to electrical system.
No fire hazard as in Electrical Systems. So can be
easily used in dangerous areas like mines.
Simple in construction, the pneumatic system
components are easy to maintain & repair.
The used air is exhausted. So no return lines as in
hydraulic system.
15. Disadvantages
Smooth and uniform speeds against loads are not
achievable as in Hydraulic systems.
Beyond certain load usage of pneumatic system is
expensive.
16. FORM OF OUTPUT
1. Linear motion
2. Rotary motion
3. Semi-rotary motion
APPLICATIONS
Pneumatic equipments can be used for applications, where
operation cycles need certain routine functions like
1. Pushing
2. Pulling
3. Lifting
4. Feeding
5. Clamping
6. Pressing
7. Forming, etc.
17. APPLICATION AREAS
1. Air brakes of automobile & trains.
2. Air engine
3. Pneumatic drills
4. Pneumatic press, power press
5. Auto motional of assembly line like automobile industry,
packaging, bottling
6. Pneumatic vehicle cleaning
7. Anti aircraft weapon
8. Pneumatic launchers
9. Vacuum pump
10. Pressure regulator
11. Cotton mills
12. Dairies
13. Forge shops
14. Foundries
15. Metal forming
16. Paper mills
17. Printings
43. PNEUMATIC STANDARDS
ISO 1219-1 Fluid power systems & components – Part 1:
Symbol for conventional use & data processing
applications.
ISO 1219-2 Fluid power systems & components – Part 2:
Circuit diagram
ISO 5599 Port marking of pneumatic directional control valves.
ISO 6432 Mounting dimensions of pneumatic cylinders: 8 to 25 mm
ISO 6431 Mounting dimensions of pneumatic cylinders: 32 to 320
mm.
CETOP RP41 Hydraulic & Pneumatic system circuit diagrams.
CETOP RP68P Identification code for ports and operators of pneumatic
control valve and other components.
ISO 8573 Quality classes of compressed air for general use
44. Classification Of Pneumatic Elements
Pneumatic elements are classified into 5 groups as
5. Working elements
Air cylinders
4. Final control elements
Flow control valve, Quick exhaust valve
3. Control elements
Directional control valves like solenoid
valves, pilot operated valves
2. Signal elements
Push button valve, Roller lever valve
1. Source & Service elements
Source – Compressor & Reservoir
Service – Filter, Regulator, Lubricator
45. 1. Source & Service elements
1. Air
2. Compressor
3. Air Filter
4. Air Pressure Regulator
5. Air Lubricator
6. Air Service Unit
7. Pneumatic Silencer
46. Air
The earth is surrounded by an envelope of air known as atmosphere.
The composition of this 12 mile thick envelope. Due to the
compressibility of air, increasing the pressure causes decrease in the
volume of air.
Boyles Law: - Boyle discovered that the pressure and the volume of
a particular quantity of gas was constant provided that the
temperature did not vary.
48. Compressors
A compressor is a machine that compresses air or another
type of gas from a low inlet pressure (usually atmospheric)
to a higher desired pressure level. This is accomplished by
reducing the volume of the gas. Air compressors are
generally positive displacement units and are either of the
reciprocating piston type or the rotary screw or rotary vane
types.
Graphic symbol
49. Types of compressor
•Piston Compressor
In this type of compressor a cylinder
bore encloses a moving piston. As the
crankshaft of the compressor rotate, the
piston moves within the cylinder,
similar to the piston in a car engine. As
the piston is pulled down, the volume
increases, creating a lower atmospheric
pressure in the piston chamber. This
difference in pressure causes air to
enter via the inlet valve. As the piston is
forced upwards the volume of air
reduces. The air pressure therefore
increases. Eventually the pressure
forces the outlet valve to open.
50. •Vane Compressor
The following figure shows a cutaway view of the sliding-vane-type
rotary compressor. The air inlet is placed where the volume of the
compression chamber is greatest, the outlet where the volume is
smallest. Consequently, as the vanes turn, the space between them is
reduced. This reduction in volume compresses the air as it travels from
the inlet to the outlet.
51. •Screw compressor
There is a current toward increased use of the rotary-type
compressor due to technological advances, which have produced
stronger materials and better manufacturing process. The
following figure shows a cutaway view of a single-stage screw
type compressor. Precise positioning of the screw is essential for
its performance. Oil provides a seal between the rotating screws
as well as lubricating the parts and cooling the air. The oil is
then separated from the air before it enters the system.
52. •Lobe compressor
In this type of compressor the rotors do not touch and
certain amount of slip exists. This slip increases as the
output pressure increases. It is therefore operated at
maximum speed for the highest efficiency. 17.3 bar is
obtainable with this type of constant displacement
compressor.
Inlet Outlet
53. Compressor Specification
Input volume of
air in liter/min
Input volume of
air in
cubic foot/min
Input voltage
in volt
Input frequency
in Hertz (Hz)
Input current
in Amp.
Output power in
Horse power (HP)
Output power in
Kilowatt (KW)
Rotating speed
of crankshaft in
revolution per
minute (rpm)
Output
pressure in bar
Output pressure
in pounds per
square inch (PSI)
Loudness of
output sound in
decibel (DB)
54. Air Filter
The air needs to be filtered to be free of moisture and contamination.
Air filter is used to do this job. The filter elements remove the particles
and moisture as small as 5 microns. Normally 30-50 micron filter is
used in pneumatic system.
Graphic symbol
55. Air pressure regulator
The pressure regulator is used to adjust the desired pressure for the
pneumatic system. This use a piston to sense downstream pressure
fluctuations. The piston, in turn, works against a set spring pressure.
As the pressure downstream drops it is sensed by the diaphragm and
the poppet valve opens. This adjusts the position of the poppet valve,
which limits the downstream pressure to the pre-set valve.
Graphic symbol
56. Air lubricator
A lubricator ensures proper lubrication of internal moving parts
pneumatics components. The proportional increase in oil mist by an
increase of air flow is achieved by the spring loaded poppet assembly.
As the flow increases and the valve opens, the area is increased and a
pressure differential created.
Graphic symbol
57. Air service unit
Filters, regulators and lubricators can be combined to ensure optimum
compressed air preparation for a specific pneumatic system.
Graphic symbol
58. Pneumatic Silencer
To decrease the noise of air in the outlet of valves, a silencer can be
used. They are made from the porous plastic or bronze. Some of them
are equipped with a control flow valve to control velocity of flow in the
outlet of valves as well.
Graphic symbol
59. 2) SIGNAL ELEMENTS
General manual
Push button
Pull button
Push/pull button
Lever
Pedal
Treadle
Manually Operated
Rotary knob
61. Solenoid
direct
Solenoid pilot
Solenoid pilot
with manual override
and integral pilot
supply
Solenoid pilot
with manual
override and
external pilot
supply
Electrically Operated
When no integral or
external pilot
supply is shown it
is assumed to be
integral
62. 3) Direction Control Elements
2/2 Direction control valve
3/2 Direction control valve
4/2 Direction control valve
5/2 Direction control valve
5/3 Direction control valve
Port & Position.mp4
63. Basically a valve is named in the following order
1. No. of positions
2. No. of ports
1. No. of positions
No. of positions Graphic symbol
2 position
3 position
1 2
1 2 3
64. 2. No. of ports Symbol
2 ports
3 ports
4 ports
5 ports
65. 1
2
3
4
5
Working ports
Symbols for valve actuations
are shown at the left hand side
or right hand side only
The lines drawn on the outside
of the square in the normal or
initial position represent the
ports
Exhaust
ports
Pressure
ports
Switching positions are shown
by squares and are drawn
adjacent to each other
Line with arrow represents
direction of flow. Shut-off
position is shown by T.
Normal position is the
switching position when the
valve is not actuated
GRAPHIC REPRESENTATION
66. Function 2/2
Normal position
Basic valves before
operators are added
Examples, push button operated
with spring return
2/2 DIRECTION CONTROL VALVE
67. Function 2/2
Operated position
Basic valves before
operators are added
Examples, push button operated
with spring return
2/2 DIRECTION CONTROL VALVE
68. Function 3/2
Normal position
Basic valves before
operators are added
Examples, push button operated
with spring return
3/2 DIRECTION CONTROL VALVE
69. Function 3/2
Operated position
Basic valves before
operators are added
Examples, push button operated
with spring return
3/2 DIRECTION CONTROL VALVE
70. Function 4/2
Normal position
Basic valves before
operators are added
Examples, push button operated
with spring return
4/2 DIRECTION CONTROL VALVE
71. Function 4/2
Operated position
Basic valves before
operators are added
Examples, push button operated
with spring return
4/2 DIRECTION CONTROL VALVE
72. Function 5/2
Normal position
Basic valves before
operators are added
Examples, push button operated
with spring return
5/2 DIRECTION CONTROL VALVE
73. Function 5/2
Operated position
Basic valves before
operators are added
Examples, push button operated
with spring return
5/2 DIRECTION CONTROL VALVE
74. Three position valves have a normal central
position that is set by springs or with a manual
control such as a lever
The flow pattern in the centre position varies
with the type. Three types will be considered
1, All ports sealed
2, Outlets to exhaust, supply sealed
3, Supply to both outlets, exhausts sealed
5/3 DIRECTION CONTROL VALVE
75. All valves types shown in the normal position
Type 1. All ports sealed
Type 2. Outlets to exhaust
Type 3. Supply to outlets
5/3 DIRECTION CONTROL VALVE
76. All valves types shown in the first operated position
Type 1. All ports sealed
Type 2. Outlets to exhaust
Type 3. Supply to outlets
5/3 DIRECTION CONTROL VALVE
77. All valves types shown in the normal position
Type 1. All ports sealed
Type 2. Outlets to exhaust
Type 3. Supply to outlets
5/3 DIRECTION CONTROL VALVE
78. All valves types shown in the second operated position
Type 1. All ports sealed
Type 2. Outlets to exhaust
Type 3. Supply to outlets
5/3 DIRECTION CONTROL VALVE
79. 4) FINAL CONTROL ELEMENTS
(Flow control valve)
Throttle valve
Graphic symbol
84. LOGIC “OR” SHUTTLE VALVE
A
C
B
A
C
B
A B
C
Input Output
A B C
OFF OFF OFF
ON OFF ON
OFF ON ON
ON ON ON
Graphic symbol
The OR logic valve has two
inputs and one output.
The output is ON if one or two
inputs are ON
And the output is OFF only if
all outputs are OFF.
85. LOGIC “AND” SHUTTLE VALVE
The AND logic valve has two
inputs and one output.
The output is ON only if all two
inputs are ON
And the output is OFF if one or
more inputs are OFF.
A B
C
A B
C
A B
C
A B
C
A B
C
Popular old
symbol
A B
C
ISO 1219-1
symbol
Input Output
A B C
OFF OFF OFF
ON OFF OFF
OFF ON OFF
ON ON ON
Graphic symbol
87. How to actuate a single acting cylinder
Position 1 Position 2
3/2 way push button operated with spring return
88. How to actuate a single acting cylinder
Position 1 Position 2
3/2 way push button operated with spring return
89. How to actuate a double acting cylinder
Position 1 Position 2
5/2 way hand lever operated valve with spring return
90. How to actuate a double acting cylinder
Position 1 Position 2
5/2 way hand lever operated valve with spring return
91. Pneumatic Actuators
1. Pneumatic Cylinders
Used for linear motion
2. Pneumatic Rotary Actuators
Used for rotary motion
3. Pneumatic Semi-Rotary Actuators
Used for linear & rotary motion
92. Pneumatic Cylinders
The cylinders converts the energy of the compressed air into
linear motion which extend or retract the piston rod.
Graphic symbol
93. Pneumatic Rotary Actuators
The rotary actuators converts the energy into a rotary motion.
Most of them is Vane air motor.
Graphic symbol
94. Pneumatic Semi-Rotary Actuators
Limited rotary motion can be achieved by incorporating a rack
and pinion into a linear actuator or as seen opposite by a Vane
Mechanism within the body of the cylinder.
Graphic symbol
95. Solenoid Valve
Graphic symbol
Direct-Acting Solenoid Valve Animation.mp4
1. Apply Current
2. Magnetic Field Builds
3. Plunger Become Attracting Magnets
4. Magnetic Force Drives Plunger
96. Working principle of Solenoid Valve
When an electric current flow through a coil, a magnetic
field is generated
The following applies to the
strength of the magnetic field.
•Increasing the numbers of
windings increases the field.
•Increasing the strength of
the current increase the field.
•Lengthening the coil reduces
the field.
98. Comparison between Pneumatic, Electro
Pneumatic & PLC based control System
Parameter Pneumatic System Electro Pneumatic
System
PLC Based Control
System
Power medium Compressed air Compressed air Compressed air
Control
medium
Compressed air Electricity(AC/DC) Electricity(voltage or
current control)
Final control
elements
Pneumatically actuated
directional control valves
Solenoid operated
directional control valve
Solenoid operated
directional control valve
Signal
processing
Using logic valves, time
delay valves, pressure
sequence valves etc
Using relays, timers,
counters, pressure
switches etc
Using program elements
for logic, time-delay,
counting etc.,
Signal
elements
Permits energy flow in
the normal position
Inhibits energy flow in
the normal position
Scans for ‘1’ signal state
to allow power flow
Timers
On-delay & Off-delay
pneumatic timers
(NO/NC type)
On-delay and Off delay
electrical/electronic
timers
Program elements in on-
delay, off-delay, and
other modes
Memory
elements
Pneumatic latch (5/2-DC
double-pilot valve)
Electrical latch
(Dominant ON and
Dominant OFF circuits)
and 5/2-DC double
solenoid valve
Setting and resetting
instructions with coils or
boxes (set priority and
reset priority)
Counters
Up-counter & down-
counter(pneumatic)
Up-counter & down-
counter(electrical)
Program elements in up-
counting and down-
counting modes
100. General Malfunctions in pneumatic system
Disturbances Possible causes Rectification
Machine is working, but
is weakening in
performance due to
slower operation
Upstream flow restriction or air
starvation
•Fit larger pipe
•Install larger compressor
Downstream flow restrictions •Check twisted tube/blocked silencers
downstream and renew
Lack of lubrication •Lubricate machines
•Fit air line lubricator
Actuator is weakening
in performance due to
slower operation
Flow regulator set too low •Re-adjust flow regulator
Tube twisted •Re-new
Piston rod bent •Repair or replace actuator
Barrel dented
Machine stop Failed pneumatic or electrical
supply
•Re-establish power supplies
Faulty products due to
faulty machine
adjustments or
misalignment of
components
Adjusting mechanism out of
alignment
•Re-adjust mechanism
Insufficient power to a
stamping or pressing actuator
•Increase pressure to the actuator or
replace the actuator with a large one
Leakage Loose joints, fittings or glands •Tighten loose joints, fittings or glands
Faulty or damaged fittings or
ruptured pipes and hoses
•Replace or repair the defective part
101. Malfunctions in Pneumatic Cylinders
Disturbances Possible causes Rectification
With valve
connected, air
escapes out of vent
hole
(Double) cup packing is
leaking
•Replace cup packing
(Double) cup packing is
loose (or valve is defective)
•Tighten cup packing
Air escapes to
atmosphere at flange
bushing
Cup packing is leaking •Replace cup packing
Cup packing is mounted in
the wrong way
•Reverse cup packing
Air escapes at piston Groove ring is defective •Fit a new grooving
End position cushion
does not respond
Lip seal on the cushioning
plunger leaks or has been
fitted the wrong way round
•Fit a new lip seal
•Re-fit the lip seal
Single-acting
cylinder piston rod
does not return to
the end position
Composition spring is
damaged
•Fit a new spring
Misalignment of
piston/piston rod or
cylinder body
Excessive jerks •Align piston/piston rod or
cylinder body
Wrong operation •Set right the operation
102. Malfunctions in Pneumatic Valves
Disturbances Possible causes Rectification
Valve leak •Dirt
•Broken seals
•Weak or broken spring
•Excessive wear
•Remove dirt
•Replace seals
•Replace spring
•Lubricate
Valve operating
mechanism fails
•Line pressure too low
•Control plunger broken
•Groove ring defective
•Corrosive damage to
surfaces by condensate
•Set control pressure
•Replace plunger
•Replace defective part
•Use proper lubricant
Valve plunger does not
return back
•Look for broken spring •Replace defective part
Sluggishness of valves •Dirt collected in the valve
especially at the groove ring
•Clean the vent hole
Valve fails to pass the
rated amount of air
•Actuating means not
stroking properly
•Bent trip cam
•Worn tripping mechanism
•Set right alignment
•Straighten trip cam
•Replace defective part
Failure of solenoid coil •Coil loosely fixed to the
solenoid stem
•Coil vibrates
•Overheating of coils
•Mismatched coils and stem
•Fix coil firmly to solenoid stem
•Fix coil firmly
•Fix coil firmly
•Use matched coils and stem
103. General Safety Measures
1. Keep your work place clean before and after work.
2. Use personal protective devices for all hazardous
jobs.
3. Follow the standard procedure while operating a
machine.
4. Know your job thoroughly
5. Inspect daily for damaged tubing, fittings & leaks
6. Check the interlock system at regular intervals
7. Repair or replace components that show signs of
wear or damage
8. Clean the spillage of grease, oil, etc., immediately
9. Never direct the compressed air towards yourself or
anyone else for cleaning
10. Never use the compressed air for cleaning away
chips and dust. Flying particles can be dangerous.
104. Basics Pneumatic circuits
A pneumatic circuit is usually designed to
implement the desired logics. However, there
are several basics circuits, which can be
integrated into the final circuit.
105. Air pilot control of double-acting cylinder
In single acting cylinder compressed air is applied on only one side of
the piston face. The other side is open to atmosphere. For return
movement of the piston spring is used. This actuator can produce
work in only one direction. Single acting cylinder with built in spring
the stroke length is limited due to natural length of spring. Single
acting cylinder are available in stroke length up to approximately
100mm. Due to construction and simplicity it is suitable for compact
short stroke.
Ex. 1)
106. Air pilot control of double-acting cylinder
Directional control valve are giving path to an air stream. It controls
actuator. The directional control valve is characterized by its number
of controlled connection or ways and by the number of switching
position.
5/2 way D.C. valve has got 2 position and 5 ports i. e. 2 exhaust, 2
outputs & 1 input.
The 5/2 way valve is used primarily as a final control element for the
control of double acting cylinder.
Ex. 2)
107. Air pilot control of double-acting cylinder
The 5/3 way valve has five ports and three position. In this valve
lines are closed in the middle position. This enables the piston rod of
cylinder to be stopped in any position over its range of stroke
although intermediate position of the piston rod cannot be located
accurately its symbol is as follows.
Ex. 3)