IN-HOUSE

362 TRAINING REPORT

PNEUMATIC SYSTEM
ETAT-362

SUBMITTED TO SUBMITTED BY
DR. VINEET KUMAR VISHAL SINGH
00320903613
MAE 6TH SEMESTER
 Table of Contents
Acknowledgement iii

1. Introduction 1
1.1 Comparison of Hydraulic and Pneumatic System
1.2 Advantages & Disadvantages of Pneumatic System
1.3 Applications
1.4 Components

2. Valves 9
2.1 Direction Control Valve
2.2 Methods of Actuation
2.3 Non-Return Valves
2.4 Flow Control Valves
2.5 Pressure Control Valves

3. Compressors 22
3.1 Piston
3.2 Double Acting
3.3 Multistage
3.4 Combined Two Stage
3.5 Diaphragm
3.6 Screw
3.7 Rotary
3.8 Lobe
3.9 Dynamic

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4. Actuators 28
4.1 Single Acting
4.2 Double Acting
4.3 Cylinder End Cushions
4.4 Gear Motor
4.5 Vane Motor
4.6 Limited Rotation Actuators
4.7 Speed Control

5. Case Study 34

References 37

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 Acknowledgement
I take this opportunity to express our sincere gratitude to the people who
have been helpful in the successful completion of our In-house training and
this project. I would like to show my greatest appreciation to the highly
esteemed and devoted technical staff, supervisors of our College. We are highly
indebted to them for their tremendous support and help during the completion
of our training and project.

I am grateful to my teachers Dr. Vineet Kumar and Mr. Urfi Khan and who
granted us the permission of in house training in the College. We would like to thanks
to all those peoples who directly or indirectly helped and guided us to complete our
training, including the instructors and technical officers of the Pneumatics Lab.

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Introduction

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 Pneumatics may be defined as branch of engineering science which deals with
the study of the behaviour and application of compressed air to power machine or
control or regulate machines. It deals with generation, transmission and control of
power using pressurized air. Gas in a pneumatic system behaves like a spring since it
is compressible.

Any gas can be used in pneumatic system but air is the most usual, for obvious reasons.
Exceptions are most likely to occur on aircraft and space vehicles where an inert gas
such as nitrogen is preferred or the gas is one which is generated on board. Actuation
of the controls can be manual, Pneumatic or Electrical actuation.

DIFFERENCES BETWEEN HYDRAULIC

AND PNEUMATIC SYSTEMS

One of the main differences between the two systems is that in pneumatics, air
is compressible. In hydraulics, liquids are not. Other two distinct differences are given
below.

The pneumatic systems have two main features:

 Pneumatic systems use compressed gas such as air or nitrogen to perform work
processes.

 Pneumatic systems are open systems, exhausting the compressed air to

atmosphere after use.

The hydraulic systems also have two main features:

 Hydraulic systems use liquids such as oil and water to perform work processes.

 Hydraulic systems are closed systems, recirculating the oil or water after use.

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S.NO. HYDRAULIC SYSTEM PNEUMATIC SYSTEM

1 It employs a pressurized liquid as fluid It employs a compressed gas usually

air as a fluid

2 Oil hydraulics system operates at Pneumatic systems usually operate at

pressure upto 700 bar 5 to 10 bar

3 Generally designed for closed systems Pneumatic systems are usually

designed as open system

4 System get slowdown of leakage Leakage does not affect the system
occurs much more

5 Valve operation are difficult Easy to operate the valves

6 Heavier in weight Light in weight

7 Pumps are used to provide pressurized Compressors are used to provide

liquids compressed gas

8 System is unsafe to fire hazards System is free from fire hazards

9 Automatic lubrication is provided Special arrangements for lubrication

needed.

Table 1.1 Comparison between Hydraulic and Pneumatic Systems

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ADVANTAGES OF
PNEUMATIC SYSTEM

 Low inertia effect of pneumatic components due to low density of air.

 Pneumatic Systems are light in weight.

 Operating elements are cheaper and easy to operate

 Power losses are less due to low viscosity of air

 High output to weight ratio

 Pneumatic systems offers a safe power source in explosive environment

 Leakage is less and does not influence the systems. Moreover, leakage is not
harmful

DISADVANTAGES OF
PNEUMATIC SYSTEMS

 Suitable only for low pressure and hence low force applications

 Compressed air actuators are economical up to 50 KN only

 Generation of the compressed air is expensive compared to electricity

 Exhaust air noise is unpleasant and silence has to be used

 Rigidity of the system is poor

 Weight to pressure ratio is large

 Less precise. It is not possible to achieve uniform speed due to compressibility

of air

 Pneumatic systems is vulnerable to dirt and contamination

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APPLICATIONS

Pneumatic systems are used in many applications. In construction, it is

indispensable source of power for such tools as air drills, hammers, wrenches, and even
air cushion supported structures, not to mention the many vehicles using air
suspension , braking and pneumatic tires.

In manufacturing, air is used to power high speed clamping, drilling, grinding, and
assembly using pneumatic wrenches and riveting machines. Plant air is also used to
power hoists and cushion support to transport loads through the plant.

Many recent advances in air – cushion support are used in the military and commercial
marine transport industry.

MATERIAL HANDLING MANUFACTURING OTHER

APPLICATIONS

Clamping Drilling Aircraft

Shifting Turning Cement Plants

Positioning Milling Chemical Plants

Orienting Sawing Coal Mines

Feeding Finishing Cotton Mills

Ejection Forming Diaries

Braking Quality Control Forge Shops

Bonding Stamping Machine Tools

Locking Embossing Door Control

Packaging Filling Turning Parts

Feeding

Sorting
Stacking

Table 1.2 Applications of Pneumatic Systems

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COMPONENTS

Pneumatic system carries power by employing compressed gas generally air as

a fluid for transmitting the energy from an energy-generating source to an energy –
use point to accomplish useful work.

Figure 1.1 Arrangement of Pneumatic System

a) Air filters
These are used to filter out the contaminants from the air.

b) Compressor
Compressed air is generated by using air compressors. Air compressors are
either diesel or electrically operated. Based on the requirement of compressed
air, suitable capacity compressors may be used.

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 c) Air cooler
During compression operation, air temperature increases. Therefore coolers are
used to reduce the temperature of the compressed air.

d) Dryer
The water vapor or moisture in the air is separated from the air by using a dryer.

e) Control Valves
Control valves are used to regulate, control and monitor for control of direction
flow, pressure etc.

f) Air Actuator
Air cylinders and motors are used to obtain the required movements of
mechanical elements of pneumatic system.

g) Electric Motor
Transforms electrical energy into mechanical energy. It is used to drive the
compressor

h) Receiver tank
The compressed air coming from the compressor is stored in the air receiver.

FUNCTIONS OF COMPONENTS

 Pneumatic actuator converts the fluid power into mechanical power to do useful
work.

 Compressor is used to compress the fresh air drawn from the atmosphere.

 Storage reservoir is used to store a given volume of compressed air.

 Valves are used to control the direction, flow rate and pressure of compressed
air.

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  External power supply (Motor) is used to drive the compressor.

 Piping system carries the pressurized air from one location to another.

Air is drawn from the atmosphere through air filter and raised to required pressure
by an air compressor. As the pressure rises, the temperature also rises and hence air
cooler is provided to cool the air with some preliminary treatment to remove the
moisture.

Then the treatment pressurized air needs to get stored to maintain the pressure. With
the storage reservoir, a pressure switch is fitted to start and stop the electric motor
when pressure falls and reached the required level, respectively.

The cylinder movement is controlled by pneumatic valve. One side of the pneumatic
valve is connected to the compressed air and silencers for the exhaust air and the other
side of the valve is connected to port A and Port B of the cylinder.

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Valves

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 Valve are defined as devices to control or regulate the commencement,
termination and direction and also the pressure or rate of flow of a fluid under pressure
which is delivered by a compressor or vacuum pump or is stored in a vessel.

FUNCTION

 They control the supply of air to power units, example cylinders

 They provide signal which govern the sequence of operation

 They act as interlock and safety devices

Valves used in pneumatics mainly have a control

function that is when they act on some process,
operation or quantity to be stopped. A control
function requires control energy, it being desirable
to achieve the greatest possible effect with the least
effort. The form of control energy will be dictated
by the valve’s mode of actuation and may be
manual, mechanical, electrical hydraulic or
pneumatic.

Figure 2.1 Simple Valve

TYPES

1. Direction control valve

2. Non return valves

3. Flow control valves

4. Pressure control valves

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 DIRECTION CONTROL VALVES

In order to control the movement of air actuators, compressed air has to be regulated,
controlled and reversed with a predetermined sequence. Pressure and flow rates of
the compressed air has to be controlled to obtain the desired level of force and speed
of air actuators.

The function of directional control valve is to control the direction of flow in the
pneumatic circuit. DCVs are used to start, stop and regulate the direction of air flow
and to help in the distribution of air in the required line.

TYPES

1. Based on construction

 Poppet or seat valves

 Ball seat valve

 Disc seat valve

 Diaphragm Valves

 Sliding spool valves

 Longitudinal slide valve

 Suspended spool valves

 Rotary spool valves

o Two way valves

o Three way valves

o Four way valves

2. Based on methods of Actuation

 Mechanical
 Electrical

 Pneumatic

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 3. Based on Size of the port

Size refers to a valve’s port size. The port sizes are designated as M5, G1/8, and
G1/4 etc. M refer to Metric thread, G refer to British standard pipe (BSP) thread.

4. Based on mounting styles

 Sub base
 Manifold

 In-line
 Valve island

PORT OLD (LE TTER) ISO (NUMBER) REMARKS

SYSTEM SYSTEM

Pressure Port P 1 Supply Port

Working Port A 2 3/2 DCV

Working Ports A,B 4,2 4/2 or 5/2 DCV

Exhaust Port R 3 3/2 DCV

Exhaust Ports R,S 5,3 5/2 DCV

Pilot Ports Z or Y 12 Pilot Line (Flow 1-2)

Pilot Ports Z 14 Pilot Line (Flow 1-4)

Pilot Ports Z or Y 10 Pilot Line (No Flow)

Internal Pilot Ports Pz, Py 81,91 Auxiliary Pilot Line

Table 2.1 Port Marking

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PORT AND POSITION

2/2 directional Valve

Ports
Position

3/2 Directional Control Valve

(Normally Closed)

3/2 Directional Control Valve

(Normally Open )

4/2 Direction Control Valve

5/2 Direction Control Valve

5/3 Direction Control Valve

Table 2.2 Ports in different positions

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POPPET DIRECTION CONTROL VA LVES

A. Ball seat valve

In a poppet valve, discs, cones or balls are used to control flow. In a
simple 2/2 normally closed valve. If the push button is pressed, ball will lift off
from its seat and
allows the air to flow
from port P to port B.
When the push
button is released,
spring force and air
pressure keeps the
ball back and closes
air flow from port P to
port B.
Figure 2.2 Ball Seat Valve

B. Disc seat poppet valve

In a disc type 3/2 way DCV, When push button is released, ports 1 and 3
are connected via hollow
pushbutton stem. If the push
button is pressed, port 3 is first
blocked by the moving valve
stem and then valve disc is
pushed down so as to open
the valve thus connecting port
1 and 3. When the push
button is released, spring and
air pressure from port 1 closes
the valve. Figure 2.3 Disc Seat Poppet Valve

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 C. Diaphragm valves
The diaphragm between the actuator and valve body hermetically
isolates the fluid from the actuator.

Closed position: When

de-energized, the valve is
closed by spring action

Open position: If the

actuator is pressurized by
the control pressure, it
simultaneously lifts the
control piston and the
valve spindle to open the
valve.
Figure 2.4 Diaphragm Valve

The valves are maintenance-free and extremely robust and can be retrofitted
with a comprehensive range of accessories, e.g. electrical position feedback,
stroke limitation or manual override.

Advantages of
poppet valves
 Response of poppet valve is very fast- short stroke to provide maximum flow
opening

 They give larger opening (larger flow) of valves for a small stroke

 The valve seats are usually simple elastic seals so wear is minimum

 They are insensitive to dust and dirt and they are robust, seats are self-cleaning

 Maintenance is easy and economical.

 They are inexpensive

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  They give longer service life: short stroke and few wearing parts give minimum
wear and maximum life capabilities

Disadvantages of
poppet valves
 The actuating force is relatively high, as it is necessary to overcome the force of
the built in reset spring and the air pressure.

 They are noisy if flow fluctuation is large.

SPOOL DIRECTION CONTROL VALVES

A. Pneumatically actuated 3/2 DCV

In normal position, the working port (2) is closed to the pressure port (1)
and open to the exhaust port (3). When the compressed air is applied through
the pilot port (12), the spool is moved against the spring.

In the actuated position, the

working port (2) is open to
the pressure port (1) and
closed to the exhaust port
(3). Thus, the application of
the compressed air to the
port 12 causes the pressure
port (1) to be connected to
the working port (2).
Figure 2.5 Pneumatically Actuated 3/2 DCV

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B. Pneumatically actuated 4/2 DCV
In a 4/2 way valve pneumatically operated DCV, Switch over is effected
by direct application of pressure. If compressed air is applied to pilot spool
through control port 12, it connects port 1 with 2 and 4 is exhausted through

Figure 2.6 Pneumatically Actuated 4/2 DCV

port 3. If the pilot pressure is applied to port 14, then 1 is connected with 4 and
line 2 exhausted through port 3. On disconnecting the compressed air from the
control line, the pilot spool remains in its current position until spool receives a
signal from the other control side.

C. Suspended Disc Direction Control Valves

This valve is quite similar to 4/2 way spool valve. In this design disc is
used instead of a
spool. This
suspended disc can
be moved by pilot
pressure or by
solenoid or by
mechanical means.
In this design, main
disc connects port 1
to either port 4 or 2. Figure 2.7 Suspended Disc DCV
The secondary seat
discs seal the exhaust port 3 whichever is not functional. These values are
generally provided with manual override to manually move the cylinder.

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 D. Rotary valves
The rotary spool directional control valve has a round core with one or
more passages or recesses in it. The core is mounted within a stationary sleeve.
As the core is rotated within the stationary sleeve, the passages or recesses
connect or block the ports in the sleeve. The ports in the sleeve are connected
to the appropriate lines of the fluid system.

Figure 2.8 Rotary Valve

By rotating the handle, core gets connected to different holes to give the
required configuration of the valve. This type of the valve can be directly
mounted on panel using bolt.

METHODS OF ACTUATION

The methods of actuation of pneumatic directional control valves depend upon the
requirements of the task. The types of actuation vary;

 Manually actuated

 Mechanically actuated

 Pneumatically actuated

 Electrically actuated

 Combined actuation

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TYPE OF ACTUATIO N TYPE OF CONTROL SYMBOL

General

Push button

Manual
Distant lever operated

Foot pedal

Spring return

Spring centred

Mechanical
Roller Operated

Idle Roller

Direct

Pneumatic Indirect, Pilot Operated

Single Solenoid

Electrical Double Solenoid

Combined Double Solenoid with pilot

operated

Table 2.3 Different types of Actuation Method

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 NON RETURN VALVES

Non return valves permit flow of air in one direction only, the other direction through
the valve being at all times blocked to the air flow. Mostly the valves are designed so
that the check is additionally loaded by the downstream air pressure, thus supporting
the non-return action.

TYPES

 Check valve
 Shuttle valve
 Restrictor check valve
 Quick exhaust valve
 Two pressure valve
Figure 2.9 Non-Return Valves

FLOW CONTROL VALVES

A flow control valve regulates the rate of air flow. The control action is limited to the
air flow passing through the valve when it is open, maintaining a set volume per unit
of time.

Figure 2.10 Flow Control Valves

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 PRESSURE CONTROL VALVE

Compared with hydraulic systems, few pressure control valves are brought into use in
pneumatics. Pressure control valves control the pressure of the air flowing through the
valve or confined in the system controlled by the valve.

Figure 2.11 Pressure Control

Valves

There are three types of pressure control valves

1. Pressure limiting valve

2. Pressure sequence valve

3. Pressure regulator or pressure reducing valve

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Compressors

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 It is a mechanical device which converts mechanical energy into fluid energy.
The compressor increases the air pressure by reducing its volume which also increases
the temperature of the compressed air. The compressor is selected based on the
pressure it needs to operate and the delivery volume.

The compressor can be classified into two main types

a. Positive displacement compressors

b. Dynamic displacement compressor

Positive displacement compressors include piston type, vane type, diaphragm type and
screw type.

PISTON COMPRESSORS

Piston compressors are commonly

used in pneumatic systems. It produces one
pulse of air per piston stroke. As the piston
moves down during the inlet stroke the inlet
valve opens and air is drawn into the cylinder.
As the piston moves up the inlet valve closes
and the exhaust valve opens which allows the
air to be expelled. The valves are spring
loaded. The single cylinder compressor gives
significant amount of pressure pulses at the
outlet port. The pressure developed is about
3-40 bar. Figure 3.1 Piston Compressor

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DOUBLE ACTING COMPRESSOR

The pulsation of air can be reduced by using double acting compressor. It has
two sets of valves and a crosshead. As the piston moves, the air is compressed on one

Figure 3.2 Double Acting Compressor

side whilst on the other side of the piston, the air is sucked in. Due to the reciprocating
action of the piston, the air is compressed and delivered twice in one piston stroke.
Pressure higher than 30bar can be produced

MULTISTAGE COMPRESSOR

As the pressure of the air increases, its temperature rises. It is essential to reduce
the air temperature to avoid damage of compressor and other mechanical elements.
The multistage compressor with intercooler in-between. It is used to reduce the
temperature of compressed air during the compression stages. The inter-cooling
reduces the volume of air which used to increase due to heat. The compressed air from
the first stage enters the
intercooler where it is
cooled. This air is given
as input to the second
stage where it is
compressed again. The
multistage compressor
can develop a pressure
of around 50bar.

Figure 3.3 Multistage Compressor

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 COMBINED TWO STAGE COMPRESSORS

In this type, two-stage

compression is carried out by using
the same piston. Initially when the
piston moves down, air is sucked in
through the inlet valve. During the
compression process, the air moves
out of the exhaust valve into the
intercooler. As the piston moves
further the stepped head provided on
the piston moves into the cavity thus
Figure 3.4 Combined Two Stage Compressor
causing the compression of air. Then,
this is let out by the exhaust port.

DIAPHRAGM COMPRESSOR

In piston compressors the

lubricating oil from the
pistons walls may
contaminate the compressed
air. The contamination is
undesirable in food,
pharmaceutical and chemical
industries. For such
applications diaphragm type
compressor can be used.
Figure 3.5 Diaphragm Compressor

The piston reciprocates by a motor driven crankshaft. As the piston moves down it
pulls the hydraulic fluid down causing the diaphragm to move along and the air is
sucked in. When the piston moves up the fluid pushes the diaphragm up causing the
ejection of air from the outlet port. Since the flexible diaphragm is placed in between
the piston and the air no contamination takes place.

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SCREW COMPRESSOR

Piston compressors are used when

high pressures and relatively low
volume of air is needed. The system
is complex as it has many moving
parts. For medium flow and
pressure applications, screw
compressor can be used. It is simple
in construction with less number of
moving parts. The air delivered is
Figure 3.6 Screw Compressor steady with no pressure pulsation. It
has two meshing screws. The air
from the inlet is trapped between the meshing screws and is compressed. The contact
between the two meshing surface is minimum, hence no cooling is required. These
systems are quite in operation compared to piston type. The screws are synchronized
by using external timing gears.

ROTARY VANE COMPRESSORS

The principle of operation of vane

compressor is similar to the
hydraulic vane pump. The
unbalanced vane compressor
consists of spring loaded vanes
seating in the slots of the rotor.
The pumping action occurs due to
movement of the vanes along a
cam ring. The rotor is eccentric to
the cam ring. As the rotor rotates,
Figure 3.7 Rotary Vane Compressor
the vanes follow the inner surface
of the cam ring. The space between the vanes decreases near the outlet due to the
eccentricity. This causes compression of the air. These compressors are free from
pulsation. If the eccentricity is zero no flow takes place.

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LOBE COMPRESSOR

The lobe compressor is used when high

delivery volume but low pressure is
needed. It consists of two lobes with one
being driven and the other driving. It is
similar to the Lobe pump used in hydraulic
systems. The operating pressure is limited
by leakage between rotors and housing.
As the wear increases during the
operation, the efficiency falls rapidly. Figure 3.8 Lobe Compressor

DYNAMIC COMPRESSORS

When very large volume of compressed air is required in applications such as

ventilators, combustion system and pneumatic powder blower conveyors, the dynamic
compressor can be used. The pressure needed is very low in such applications. The
impeller rotates at a high speed. Large volume of low pressure air can be provided by

Figure 3.9 Dynamic Compressor

blowers. The blowers draw the air in and the impeller flings it out due to centrifugal
force. Positive displacement compressors need oil to lubricate the moving parts,
whereas the dynamic compressors have no such need. The efficiency of these
compressors is better than that of reciprocating types.

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Actuators

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 Actuators are output devices which convert energy from pressurized hydraulic
oil or compressed air into the required type of action or motion. In general, hydraulic
or pneumatic systems are used for gripping and/or moving operations in industry.
These operations are carried out by using actuators.

Actuators can be classified into three types.

1. Linear actuators: These devices convert hydraulic/pneumatic energy into linear

motion.
2. Rotary actuators: These devices convert hydraulic/pneumatic energy into rotary
motion.
3. Actuators to operate flow control valves: these are used to control the flow and
pressure of fluids such as gases, steam or liquid.

The construction of hydraulic and pneumatic linear actuators is similar. However they
differ at their operating pressure ranges. Typical pressure of hydraulic cylinders is
about 100 bar and of pneumatic system is around 10 bar.

SINGLE ACTING CYLIND ER

These cylinders produce

work in one direction of motion
hence they are named as single
acting cylinders. The
compressed air pushes the
piston located in the cylindrical
barrel causing the desired
motion. The return stroke takes
place by the action of a spring.
Generally the spring is
Figure 4.1 Single Acting Cylinder
provided on the rod side of the
cylinder.

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DOUBLE ACTING CYLIND ER

The main parts of a hydraulic double acting cylinder are: piston, piston rod,
cylinder tube, and end caps. The piston rod is connected to piston head and the other
end extends out of the cylinder. The piston divides the cylinder into two chambers
namely the rod end side and piston end side. The seals prevent the leakage of oil
between these two
chambers. The cylindrical
tube is fitted with end
caps. The pressurized oil,
air enters the cylinder
chamber through the
ports provided. In the rod
end cover plate, a wiper
seal is provided to
prevent the leakage of oil
and entry of the Figure 4.2 Double Acting Cylinder
contaminants into the
cylinder.

The combination of wiper seal, bearing and sealing ring is called as cartridge assembly.
The end caps may be attached to the tube by threaded connection, welded connection
or tie rod connection. The piston seal prevents metal to metal contact and wear of
piston head and the tube. These seals are replaceable. End cushioning is also provided
to prevent the impact with end caps.

CYLINDER END CUSHIONS

Double acting cylinders generally contain cylinder cushions at the end of the
cylinder to slow down the movement of the piston near the end of the stroke.
Cushioning arrangement avoids the damage due to the impact occurred when a fast
moving piston is stopped by the end caps. Deceleration of the piston starts when the
tapered plunger enters the opening in the cap and closes the main fluid exit. This
restricts the exhaust flow from the barrel to the port. This throttling causes the initial
speed reduction. During the last portion of the stroke the oil has to exhaust through
an adjustable opening since main fluid exit closes. Thus the remaining fluid exists

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 through the cushioning valve.
Amount of cushioning can be
adjusted by means of cushion
screw. A check valve is
provided to achieve fast break
away from the end position
during retraction motion. A
bleed screw is built into the
check valve to remove the air
bubbles present in a hydraulic
type system.
Figure 4.3 Cylinder End Cushions

GEAR MOTOR: A ROTARY ACTUATOR

It consists of two inter meshing gears inside

a housing with one gear attached to the
drive shaft. The air enters from the inlet,
causes the rotation of the meshing gear due
to difference in the pressure and produces
the torque. The air exists from the exhaust
port. Gear motors tend to leak at low speed,
hence are generally used for medium speed
applications.
Figure 4.4 Gear Motor

VANE MOTOR: A ROTARY ACTUATOR

A rotary vane motor consists of a

rotor with sliding vanes in the slots
provided on the rotor. The rotor is
placed eccentrically with the housing.
Air enters from the inlet port, rotates
the rotor and thus torque is produced.
Air is then released from the exhaust
port (outlet).

Figure 4.5 Vane Motor

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LIMITED ROTATION ACTUATORS

It consists of a single rotating vane connected to output shaft. It is used for double
acting operation and has a maximum angle of rotation of about 270°. These are
generally used to actuate dampers in robotics and material handling applications.
Other type of limited rotation actuator is a rack and pinion type actuator.

Figure 4.6 Limited Rotation Actuator

SPEED CONTROL

For an actuator, the operational speed is determined by the fluid flow rate and the
cylinder actuator area or the motor displacement. The speed can only be controlled by
adjusting the fluid flow to the actuator, because the physical dimension of the actuator
is fixed. Since the air is compressible, flow control is difficult as compared to the
hydraulic system. There are various ways of controlling the fluid flow.

Figure 4.7 Speed Control Arrangement

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One of the method is that a pump having fixed displacement is kept along an actuator.
Thus, the fluid goes either to the pump or the actuator. When the direction control
valve moves from its centre position the actuator of area ‘A’, the piston moves with a
velocity.

v = 𝑉/𝐴
If the pump delivery volume ‘V’ can be adjusted by altering swash plate angle of a
piston pump or by using a variable displacement vane pump, no further speed control
will be needed.

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Case Study

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 To design a pneumatic circuit to accomplish a simple operation where a double-
acting cylinder is used to transfer parts from a magazine. The cylinder is to be advanced
either by operating a push button or by a foot pedal. Once the cylinder is fully advanced,
it is to be retracted to its initial position. A 3/2-way roller lever valve is to be used to
detect the full extension of the cylinder.

Figure 5.1 Magazine Ejection Setup

COMPONENTS USED

The pneumatic components which can be used to implement the mentioned task are
as follows:

 Double acting cylinder

 3/2 push button valve
 3/2 roller valve
 Shuttle valve
 3/2 foot pedal actuated valve
 5/3 pneumatic actuated direction control valve
 Compressed air source and connecting piping

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WORKING

Figure 5.2 Magazine Ejection Mechanism

According to the problem stated, upon actuation of either the push button of valve
(S1) or the foot pedal valve (S2), a signal is generated at 1 or 1(3) side of the shuttle
valve. The OR condition is met and the signal is passed to the control port 14 of the
direction control valve (V2). Due to this signal, the left position of V2 is actuated and
the flow of air starts. Pressure is applied on the piston side of the cylinder (A) and the
cylinder extends. If the push button or pedal valve is released, the signal at the
direction control valve (V2) port is reset. Since DCV (V2) is a double pilot valve, it has
a memory function which doesn’t allow switching of positions. As the piston reaches
the rod end position, the roller valve (S3) is actuated and a signal is applied to port 12
of the DCV (V2). This causes actuation of right side of DCV (V2). Due to this actuation,
the flow enters at the rod-end side of the cylinder, which pushes the piston towards
left and thus the cylinder retracts.

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 References
 Boltan, W., Mechatronics: electronic control systems in mechanical and electrical
engineering, Longman, Singapore, 1999

 Boucher, T. O., Computer automation in manufacturing - an Introduction,

Chapman and Hall, 1996

 Blackburn,J. F.,G.Reethof, and J. L. Shearer, Fluid Power Control, New York:

Technology Press of M. I. T. and Wiley

 Hasebrink J.P., and Kobler R., “Fundamentals of Pneumatics/electropeumatics”,

FESTO Didactic publication No. 7301, Esslingen Germany, 1979.

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