Components of Pneumatic System

Pneumatic System
Use compressed atmospheric air as the operating medium A pneumatic system is open Pressure rise in a gas can be distinctly leisurely The slow response of an air compressor necessitates storage

of compressed air at the required pressure in a receiver vessel

The volume of this vessel is chosen so there are minimal

deviations in pressure arising from flow changes in loads

Pneumatic System
Deviations in air pressure are smaller, and compressor control is

easier if a large receiver feeds many loads.

A large number of loads statistically results in a more even flow of

air from the receiver, also helping to maintain a steady pressure

Therefore, compressed air is produced as a central service which

is distributed around the site in a similar manner to electricity, gas and water.

Pneumatic System
Behavior of a gas subjected to changes in pressure, volume

and temperature is governed by the general gas equation. PV = nRT

A compressor increases air pressure by reducing its

volume, resultant rise in temperature.

A pneumatic system must therefore incorporate some

method of removing this excess heat.

Pneumatic System
Atmospheric air contains water vapour As compressed air is cooled, and if left the resultant water

droplets would cause valves to jam and corrosion to form in pipes.

An after-cooler must therefore be followed by a water

separator.
Often after coolers and separators are collectively

called, primary air treatment units.

Pneumatic System
Dry cool air is stored in the receiver, with a pressure

switch used to start and stop the compressor motor, maintaining the required pressure.

Pneumatic System
Ideally, air in a system has a light oil mist to reduce chances of

corrosion and to lubricate moving parts in valves, cylinders and so on.

The exit air from the receiver passes through a unit which

provides the lubricating mist along with further filtration and water removal.
This

process is commonly called secondary air

treatment.

Pneumatic System
Air in the receiver is held at a slightly higher pressure than

needed to allow for pressure drops in the pipe lines.

A local pressure regulation unit is then employed with the

secondary air treatment close to the device using air.

Composite devices called service units comprising water

separation, lubricator and pressure regulation are available for direct line monitoring close to the valves and actuators

of a pneumatic system.

Fig. Represents the components used in the production of a reliable source of compressed air

Component parts of a pneumatic system

Compressor
Positive displacement devices (where a fixed volume of air is

delivered on each rotation of the compressor shaft) and

Dynamic devices such as centrifugal or axial blowers.

 A compressor is selected by the pressure it is required to

work at and the volume of gas it is required to deliver.

Pressure at the compressor outlet is called the working

pressure and is used to specify the compressor.

Pressure at the operating point is called, the operating

pressure and is used to specify valves, actuators and other operating devices.

Piston compressors

Piston compressors
Most common type of compressor

Piston descends during the inlet stroke the inlet valve opens and air is

drawn into the cylinder.

As the piston passes the bottom of the stroke, the inlet valve closes and

the exhaust valve opens allowing air to be expelled as the piston rises
Spring-loaded valves are used, which open and close under the action of

air pressure across them

Gives significant pressure pulses at the outlet port

 A compressor which produces one pulse of air per piston

stoke is called a single acting compressor.

A more even air supply can be obtained by the double

acting action of the compressor

 single stage compressor - go direct from atmospheric to

required pressure in a single operation.

If the exit pressure is above about 5 bar in a single-acting

compressor, the compressed air temperature can rise to

over 200oC and the motor power needed to drive the compressor rises accordingly.

 pressures over a few bar it is far more economical to use a

multistage compressor with cooling between stages

Normally two stages are used for pneumatic pressures of

10 to 15 bar, but multistage compressors are available for pressures up to around 50 bar

 Multistage compressors can be manufactured with multi-

cylinders

 Multi stage compressor - with a single cylinder and a

double diameter piston

Flexible diaphragm compressor

There is contact between pistons and air which may introduce

small amounts of lubrication oil from the piston walls into the air. This very small contamination may be undesirable in food and chemical industries. common way of giving a totally clean supply by incorporating a flexible diaphragm between piston and air.

 Piston compressors are used where high pressures (> 20 bar)

and relatively low volumes (< 10,000 m3 hr-1) are needed, but

are mechanically relatively complex with many moving parts.

Many applications require only medium pressure (< 10 bar) and

medium flows (around 10,000 m3 hr-1).

 For these applications, rotary compressors have the advantage of

simplicity, with fewer moving parts rotating at a constant speed, and a steady delivery of air without pressure pulses.

Rotary screw compressor

Consists of two intermeshing rotating screws with minimal

(around 0.05 mm) clearance. As the screws rotate, air is drawn into the housing, trapped between the screws and carried along to the discharge port, where it is delivered in a constant pulse-free stream
Dry n Wet type..

Vane compressor
Rotary vane compressors consist of a rotor with multiple sliding vanes that are mounted eccentrically in a casing. As the rotor rotates,

gas is drawn into areas of increasing volume

and discharged as compressed gas from areas of small volume.

The lobe compressor (Roots blower)

As the lobe impellers rotate, gas

is trapped between the lobe impellers and the compressor

case where the gas is pressurized

through the rotation of lobes and then discharged.

The lobe compressor (Roots blower)

Positive displacement compressor

High delivery volume but low

pressure (1-2 bar). Operating pressure is mainly limited by leakage between rotors and housing. To operate efficiently, clearances must be very small, and wear leads to a rapid fall in efficiency

Air receivers and compressor control

 Its volume - reduces pressure fluctuations arising from

changes in load and from compressor switching.

Air coming from the compressor will be warm and the

large surface area of the receiver dissipates this heat to the surrounding atmosphere.
Any moisture left in the air from the compressor will

condense out in the receiver, so outgoing air should be taken from the receiver top.

Air treatment
Atmospheric air contains many harmful impurities (smoke, dust, water

vapour) and needs treatment before it can be used.

In general, this treatment falls into three distinct stages, First, inlet filtering removes particles which can damage the air

compressor.
Next, there is the need to dry the air to reduce humidity and lower the

dew point.
This is normally performed between the compressor and the receiver

and is termed primary air treatment.

 The final treatment is to remove moisture and dirt and the

introduction of a fine oil mist to aid lubrication - is generally

termed secondary air treatment.

Filters
Inlet filters are used to remove dirt and smoke particles before

they can cause damage to the air compressor.

Classified as dry filters with replaceable cartridges or wet filters

where the incoming air is bubbled through an oil bath then passed through a wire mesh filter.
Dirt particles get attached to oil droplets during the bubbling

process and are consequently removed by the wire mesh.

 Filters are classified according to size of particles they will

stop.

[Dust particles are generally larger than 10m, whereas smoke and

oil particles are around 1m.]

A filter can have a nominal rating or an absolute rating

Micro-filters with removable cartridges passing air from

the centre to the outside of the cartridge case will remove

99.9% of particles
Coarse filters, constructed out of wire mesh and called

strainers, are often used as inlet filters

Air dryers
When pneumatic components wear or become corroded as a

result of moisture, they consume more compressed air - and

lose energy efficiency.
In bulk air systems a simple after cooler followed by a

separator unit where the condensed water collects and can be drained off.

 Figure shows a typical water trap and separator. Air flow through the unit undergoes a sudden reversal of

direction and a deflector cone swirls the air

Both of these cause heavier water particles to be flung out

to the walls of the separator and to collect in the trap

bottom from where they can be drained.

Lubricators
Pneumatic system components and almost all pneumatic

tools perform better when lubricated with oil.

Lubricated valves, cylinders and air motors have proper

operation and long service life.

Too little oil can allow excessive wear and cause premature

failure.

Lubricators
Excessive oil in the pipeline is wasteful and can become a

contaminant in the ambient area as it is carried out of tools

and valves by the air exhaust.
Intermittent lubrication may be the worst condition of all

because the oil film can dry out and form sludge or varnish on the internal surfaces of the equipment.

 As air enters the lubricator its velocity is increased by a venturi

ring causing a local reduction in pressure in the upper chamber.

The pressure differential between lower and upper chambers causes

oil to be drawn up a riser tube, emerging as a spray to mix with the air.
The needle valve adjusts the pressure differential across the oil jet

and hence the oil flow rate.

The air-oil mixture is forced to swirl as it leaves the central cylinder

causing excessively large oil particles to be flung out of the air stream.

Pressure regulation
Supplies air at constant pressure regardless of flow variation or upstream

pressure.
Helps operate the system more economically by minimizing the amount

of pressurized air that is wasted.

Helps promote safety by operating the actuator at reduced pressure
Extends component life because operating at higher-than-recommended

pressures increases wear rate and reduces equipment life

 Outlet pressure is sensed by a diaphragm preloaded with an adjustable

pressure setting spring.

The diaphragm falls if the outlet pressure is too high, and rises if the

pressure is too low.

If outlet pressure falls, the inlet poppet valve is pushed open admitting

more air to raise pressure.

If the outlet pressure rises, the diaphragm moves down closing the inlet

valve and opening the central vent valve to allow excess air to escape from
the load thereby reducing pressure.
In a steady state the valve will balance; dithering between admitting and

venting small amounts of air to keep load pressure at the set value.

Actuators:

Cylinders
Pneumatic cylinders offer a straight rectilinear motion classified as light. Medium and heavy duty Functionally, cylinders may be single acting and double acting. They may be further classified as diaphragm cylinder, duplex

cylinder, through rod cylinder etc.

End position cushioning of cylinders - if the cylinders do not travel

up to the end of stroke, designers need not go for cushioned

cylinders.
The piston rods of cylinders are given special treatment as it is the

highly stressed part.

Single Acting Cylinder

The compressed air is fed only in one side. Produce work only in one direction. The return movement of the piston is effected by a built-in

spring or by application of an external force.

Construction of Single Acting Cylinder

Generally, a single acting cylinder is made of the following elements:
(i) The cylinder body (tube)
(ii) Two end covers (one may be an integral part of the cylinder tube) (iii) A piston

(iv) Piston rod

(v) V-cup seal (vi) O-ring (vii) Bush at bearing to guide the piston rod (viii) Built-in spring.

 The stroke is limited by the compressed length of the spring.

There is possibility of the spring to bulge out and scratch the

finely finished piston-rod surface, thereby damaging it.

The air has to first overcome the pressure of the spring and

hence some power is lost before actual stroke of the piston starts.
Spring Size effect..

 Using a bigger single acting (SA) cylinder is quite

uneconomical and, therefore, such a cylinder should not

be used for a stroke length of more than 100 mm in general.

Double Acting Cylinder

The force exerted by the compressed air moves the

piston in two directions

Used particularly when the piston is required to

perform work not only on the advance movement but

also on the return.
Buckling and bending must be considered

A DA cylinder consists of:

(i) Cylinder tube (ii) Piston unit (iii) Piston rod (iv) Double cup packing on piston, rod packing of '0' rings

(v) End covers

(vi) Bronze rod guide (vii) Port connection (viii) Cushion-assembly (in the case of cushion cylinder)

Types of Double acting cylinder

Through rod cylinder: Piston rod extended on both ends of

the piston. Ensures equal force and speed on both sides of the
cylinder
Cushion end cylinder: Air at the end of its exhaust from the

cylinder is regulated out, so that impact of the piston to the end can be avoided

 Tandem Cylinder: two cylinders are arranged in series so

that the force obtained from the cylinder is almost double

Impact cylinder: piston rod is specially designed to

withstand high force or impact. Cylinder can work at high

velocity
Cable cylinder: cable is attached to each side of the piston

eliminating piston rod (Rod less cylinder), Gives longer

stroke length on a smaller installation space

 Rotary cylinder(Turn cylinder): Piston rod is having a gear

profile meshing against a worm wheel in such a manner that

with linear movement of the piston rod, the worm wheel rotates at specific angle

Cushion Assembly
Gradual deceleration of the piston near the end of its stroke.

It is especially helpful when the piston rod is connected to a

heavy load and the piston is at a high speed.

It reduces the shock or the impact load on the end covers of

the cylinder.

cushion is a chamber of

relatively small diameter into

which a cushion nose or collar enters as the piston nears the end of its stroke so that air is trapped in the cylinder tube between the

piston and cylinder cover and is

bled-off slowly, reducing the rate of piston travel

 The cover contains a cushion needle Passage to needle from the inside face of the cover

Contains a ball check valve which has a passage between

the inside face of the cover and the air inlet port.
When the cushion nose or collar approaches the cover and

enters the cushion bore, the air is trapped between the piston and the cover
The cushion needle is set so that the air is bled-off to the

port connection at the proper rate to slow down the piston

and reduce the shock.

 For the return stroke, if the air is fed via the cushion

chamber itself, initial motion would be extremely slow

since the air acting only on the cushion nose section, the

force available would be low, and possibly not enough to move the piston.
The use of a ball-check valve will overcome this difficulty

by allowing air to flow freely to the piston face for moving

the piston away from the cushion bore on the return stroke.

 Piston speed:

Average speed 0.1 to 1.5 m/s Impact cylinder 10m/s

Piston force: Dependent on air pressure, the cylinder

diameter and frictional resistance of the seating components

Fth = AP
A = Useful piston area

P = Pressure of air

 D = Diameter of the Piston d = Diameter of the Piston rod A1 = Area of the cross section of the piston A2 = Effective area of the cylinder piston rod end P = Air pressure

Ff = Cylinder forward force

Fr = Return force of cylinder FR = Friction force

Ff = A1P FR
Fr = A2P - FR

 Air consumption = Piston stroke X Piston Area X Compression Ratio

Pneumatic Valves
Valves are fluid power elements used for controlling and

regulating the working medium,

Start and stop pneumatic energy Control the direction of flow of compressed air Control the flow rate of the compressed air Control the pressure rating of the compressed air

There are various types of valves available in the family of compressed air system but according to their main function, they may be divided into four broad groups: (i) Direction control valves (ii) Direction control check valves or non-return valves (iii) Flow control valves (iv) Pressure control valves

Directional Control Valves (D.C. Valves)

Used mainly to direct the flow of the pressure fluid

in the desired directions.

The main functions of these valves are to start,

stop and regulate the direction of air flow and help

distribution of air in the desired line.
They can be actuated to assume different positions

by

various

actuating

mediums,

viz.

electrical,

mechanical, pneumatic, or other modes of control.

Valve Position
A direction control valve has two or three
working positions generally. They are: (i) Normal or zero position (natural) or neutral position (ii) Working position (the working position can be two or more)

Direction control valve has generally two, three, four or five ports or openings - termed ways or ports. The ways are designated by letters or alphabets such as:
P =compressor line port (pump in the case of hydraulics)
R =exhaust port (T in the case of hydraulics) {A, B} =working ports to cylinders or motors

 In direction control valves with spring return, the neutral

position is defined as the position to which the valve

returns after the actuating force has been withdrawn.

Neutral position is indicated as "0". The starting position or initial position is defined as the

position taken up by the valve (due to spring in-case of spring actuated D.C. valve) after installation.
The valve attains the working positions when actuated.

Valve symbol
A valve position is represented by a square The number of squares is equal to the number of distinct

positions that the valve can take up Inside a square, the lines indicate the flow and the arrows, the directions of flow Cut-offs of air flow is shown by short traverse lines inside the square Connections to inlet and outlet ports are drawn only to a connecting position, i.e. initial position or neutral. The other positions are obtained by shifting the set of squares until the connections match the corresponding lines in the square. The connections are denoted by English Capital Letters (alphabets)

 The other positions are obtained by shifting the set of

squares until the connections match the corresponding lines in the square. The connections are denoted by English Capital Letters (alphabets) The working line connections are indicated by A, B, C. The compressor line connection (the pressure source) is indicated by P, and return lines by R, S and T.

Types of control valve

There are essentially three types of control valve: poppet valves, spool valves and rotary valves Poppet valves In a poppet valve, simple discs, cones or balls are used in conjunction with simple valve seats to control flow.

 Poppet valves are simple, cheap and robust A major disadvantage of poppet valves is the force needed

to operate them.

Large capacity valves need large valve areas, leading to

large operating force.

They are mainly found in low pressure pneumatic systems.

Spool valves
Spool (or slide) valves are constructed with a spool moving

horizontally within the valve body

Raised areas called 'lands' block or open ports to give the

required operation.
The operation of a spool valve is generally balanced.

 In the valve construction, pressure is applied to opposing

faces D and E and low tank pressure to faces F and G.

There is no net force on the spool from system pressure,

allowing the spool to be easily moved.

 Advantage of spool valves; different operations can be achieved with a common body and different spools. This obviously reduces manufacturing costs.

 Spool valves are operated by shifting the spool. This can be achieved by button, lever or striker, or

remotely with a solenoid.

Solenoid-operated valves commonly work at 24 V DC or

110 V AC.
A solenoid can exert a pull or push of about 5 to 10 kg,

adequate for most pneumatic spool valves, but is too low for direct operation of large capacity hydraulic valves. Here pilot operation must be used,

Rotary valves
Rotary valves consist of a rotating spool which aligns with

holes in the valve casing to give the required operation. Rotary valves are compact, simple and have low operating forces.

Check valve
Check valves only allow flow in one direction and, as such,

are similar in operation to electronic diodes. Free flow direction is normally marked with an arrow on the valve casing.

Shuttle valves
A shuttle valve, also known as a double check valve, allows

pressure in a line to be obtained from alternative sources.

Fast exhaust valve

Used to vent cylinders quickly.

Used with spring return (single-acting) pneumatic cylinders.

Consists of a movable disc which allows port A to be

connected to pressure port P or large exhaust port R.

Fast exhaust valves are usually mounted local to, or directly

onto, cylinders and speed up response by avoiding any delay from return pipes and control valves

twin pressure valve - AND GATE.

Here an output is produced if both the input signals are fed

Sequence valves
The sequence valve is used where a set of operations are to be

controlled in a pressure related sequence. Typical example where a workpiece is pushed into position by cylinder 1 and clamped by cylinder 2

 Sequence valve V 2 is connected to the extend line of cylinder

1.
When this cylinder is moving the workpiece, the line pressure is

low, but rises once the workpiece hits the end stop.
The sequence valve opens once its inlet pressure rises above a

pre-set level
Cylinder 2 then operates to clamp the workpiece. A check valve across V 2 allows both cylinders to retract

together.

Flow control valves

Flow control valves influence the volumetric flow of the

compressed air in both directions. Ex: Throttle valve - used for speed control of cylinders. [Care throttle valve does not close fully]

One-way flow control valve

The air flow is throttled in one direction only. In the opposite direction, the air can flow freely through

the opened check valve

 Fundamentally, there are two types of throttling circuits for

double-acting cylinders:
Supply air throttling

Exhaust air throttling

Supply air throttling: One-way flow control valves are installed so

that the air entering the cylinder is throttled.

The exhaust air can escape freely through the check valve of the

throttle valve on the outlet side of the cylinder.

The slightest fluctuations in the load on the piston rod, lead to

very large irregularities in the feed speed.

 A load in the direction of movement of the cylinder accelerates the

cylinder beyond the set value.

Therefore supply air throttling can be used for single-acting and small

volume cylinders.

Exhaust air throttling

The supply air flows freely to the cylinder and the exhaust air

is throttled.
In this case, the piston is loaded between two cushions of air.

Arranging throttle relief valves in this way contributes

substantially to the improvement of feed behaviour.

Time delay valve

The time delay valve is a combined 3/2-way valve, one way flow

control valve and air reservoir.

 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.

 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.

Time response with delay-on

Time response with delay-off

Signal shortening / signal switch-off