Pneumatics Part 2

7/3/2009
• Different types of actuation • Manual
– Manual
– Mechanical
Pneumatics Part 2 – Pneumatic
– Electrical
– Combined
Compressed air systems, components and
circuits
By
Amaren P. Das
amaren.das@gmail.com
Mechanical
NFC TS 2009 Pneumatics APDas 2
Pneumatic • Poppet valve: long service life but large actuation
force is required
– Ball valve
– Disk seat valve
Disk seat valve
• Slide valve
Electrical Combined – Longitudinal slide valve (spool valve)
– Longitudinal flat slide valve
– Plate slide valve
NFC TS 2009 Pneumatics APDas 3 NFC TS 2009 Pneumatics APDas 4
1
7/3/2009
• Has two ports and two position • Construction and working principal of 3/2 valve
• Rarely used except as an on‐off valve – Explain the working principle of valve
• Normally of ball seat construction – Find what the circuit does
3/2 normally closed Controlling a single
3/2 normally closed acting cylinder
disk seat
NFC TS 2009 Pneumatics APDas 5 ball seat NFC TS 2009 Pneumatics APDas 6
• Hand operated • Pilot actuation • Has 4 port and 2 position

– 12 pilot line
• Similar in construction to two 3/2 valve
– Spring to reset
– Can be configured as • One valve normally closed other normally open
normally open or normally
closed
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7/3/2009
• 4 ports and 3 position • Types of 5/3 valve
• Center position blocked – Blocked center
• The cylinder is fixed at its position when the
• Can be used to hold cylinder valve is un‐actuated
at the middle of the stroke
– Open center
• Position of the cylinder is not • Generally used when the piston of the
accurate as extra load will cylinder is to be moved by hand or some
change the position other tool during operation cycle
– Pressure center
• Same as the blocked center but any leak
through the seals are compensated and
pressure is always maintained
• Construction and working • Stops flow in one
principal of 5/3 valve direction and permits
– Has 5 working ports flow in the reverse
– 3 switching positions direction
– If no signal is applied at
If no signal is applied at
either of the two ports, the • Blocking in one direction
valve remains spring‐ can be effected by cone,
centered in the middle balls, plates or diaphragm
position
– Notice the two springs on
both side in the symbol it is
essential
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7/3/2009
• Has to inlets 1 and 1(3) and one outlet • It has two inlets 1 and 1(3)
2 • If any of the inlets is
• When signal is present on both inlet pressurized the signal is
port then only signal is available on available at the outlet port
output port 2. • The valve performs the logic
• The signal which is last applied is
The signal which is last applied is OR function
OR function
passed through the port. • When air flow is reversed , the
• One input signal on 1 or 1(3) block the seat remains in its previously
flow due to differential pressure assumed position because of
the pressure condition
• If inputs are at different pressure, the
lower of the two passes through the • If cylinder is to be operated
from one or more positions,
valve one or more shuttle valve
• It function as an AND gate must be used
• Actuating cylinder
• Used to increase the piston
from two different
speed
positions.
• It opens a large exhaust area
• What changes are
near the cylinder port.
required if we want
required if we want
to actuate it from • Lengthy return time is Flow from 1 to 2
three positions ? avoided in single acting
cylinder
Flow from 2 to 3
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7/3/2009
• Shut off valves are non‐
adjustable valve, which
releases or shut off flow
in both directions
• Controls volumetric flow • Flow is controlled only
of compressed air in both while flowing from 1 to 2
directions. • Flow from 2 to 1 is free of
• It throttles the air by
y any obstruction
increasing or decreasing • Is used in speed
the flow area regulation of cylinder
• It is normally adjustable
• It is used to control the
speed of cylinder
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7/3/2009
• For a double acting cylinder should inlet air be throttled
or the exit air ? And why ?
• In case of inlet throttling there will be huge fluctuation of
speed in the cylinder motion if the load on the cylinder
slightly changes, i.e. while crossing roller limit switch.
li h l h i hil i ll li i i h
• Load variation on the cylinder hardly effects the speed of
cylinder, as the piston is traveling between two air
compressed air.
Inlet throttling Exhaust throttling
• Maintains constant pressure at the outlet even with fluctuating • If the pressure in line 12 is
inlet pressure greater then the spring
• The inlet pressure must be greater than required pressure force, the out port 2 is
connected to port 1.
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7/3/2009
• It is a combination of 3/2 valve , one flow control valve
and a reservoir .
• 3/2 valve can be normally open or closed valve
• The time delay is between 0 to 30 sec
• 3/2 valve actuates only after the reservoir is completely
filled to a pressure which counters the spring force.
• The rate of flow to the reservoir is determined by the
flow control valve, which sets the time interval.
• Figure in next page
• For trouble free and continuous performance of control
system, air supply should be
– Maintained at required pressure
– Dry
– Clean
• Equipment used in generation and prepration of air
d d f
– Inlet filter
– Compressor
– Reservoir / receiver
– Air dryer
– Air filter with water separate
– Pressure regulator
– Lubricator if required
– Drainage points
7
7/3/2009
• Pressure Level • Reciprocating
– Piston
– Components are designed for maximum pressure – Diaphragm ( no contamination, used in food and pharma
up to 8‐10 bar industry)
– Practical experience has shown that approx 6 bar
Practical experience has shown that approx 6 bar • Rotating Piston
g
– Sliding vane
should be used for economic operation
– Twin shaft screw
– Pressure loss up to .1 bar must be expected due to – Roots compressor
restrictions bends, leaks and pipe‐run • Flow compressor (used high flow rate but low pressure)
– The compressor should generate pressure – Radial flow compressor
between 6.5 to 7 bar – Axial flow compressor
• Most common • It the first component down stream of a compressor
• Why it is needed?
• Wide range of pressure and delivery rate – Stabilizes compressed air, removes pressure fluctuation
• For high pressure use multistage – Stores the air, so that compressor does not have to run
continuously
• Optimum range of pressure for reciprocating – Stored air can be used as an when required by the system
compressor – Provides the compressed air to cool down, portion of the
– Up to 4 bar Single stage moisture is removed the air
– Up to 15 bar Double stage
– Over 15 bar Treble Stage
8
7/3/2009
• Use nomogram to determine • The service unit consisting of Filter‐ separate ,

the size of Reservoir Regulator and Lubricator, also called FRL unit
– Delivery volume, QL = 20 • Filter‐ separate is used to filter out condensed water,
contamination and excess oil.
m3/min
– Pore size determines the smallest particle that
– Switching cycle per hour,
can be filtered out
can be filtered out
Z=20 l/h
– The usual pore size is between 5 micron to 40
– Differential pressure
micron Filter
(higher set point – lower
set point), ΔP= 0.1 bar – Condensate collected should be manually
drained out.
– Result: Receiver size
,VB=15m3 – Over use of filter may lead to heavy energy loss,
due to pressure drop across it
Filter and separate
manual
Construction of FRL unit
• Regulator is nothing but a pressure regulator
• Lubricator • Filter construction • Lubricator construction
– For some components lubrication is damaging
‐>damages seals
– Control units do not need lubricated air
– Power components may need lubrication
Power components may need lubrication Pressure regulator
Pressure regulator
with indiacator
– Lubrication by means of mist lubrication is
required when
• Extremely rapid oscillating motion is required
• Cylinders of large diameter
– Mist Lubrication is done based on venturi action
Lubricator
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7/3/2009
Air distribution
• Distributed using Pipes
• Pipe diameter should be selected
using Nomogram
• Pipe line must be installed in
direction of flow with a gradient of 1
to 2 degree
• Any branching of air consumption
point where lines run horizontaly
should always be installed on the
upper side of main line
• Condensate removal are installed on
the under side of main line
Ring Main
• Plastic Pipes are mostly used as no brazing,
welding or joining with threaded components
are required
yp pp g y
• Types of main piping lay out
Interconnected Main
– Branch Line
– Ring Line – should normally be used
– Interconnected circuit
• Ring main ensures largely constant pressure
conditions
10
7/3/2009
Th k
Thank you
NFC TS 2009 Pneumatics APDas 41
11

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7/3/2009

• Hand operated • Pilot actuation • Has 4 port and 2 position

• Use nomogram to determine • The service unit consisting of Filter‐ separate ,

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