Level 1 Pneumatics Exercises Grey Logo Version Feb 2012 PDF

Pneumatics
Level 1
Collection of
Exercises
2012 MECHATRONICS International, Lichfield
2001 MECHATRONICS International Ltd, Lichfield
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in
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permission of MECHATRONICS International Ltd.
Part No. MEX001
MECHATRONICS International Ltd

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Introduction
These exercises and solutions have been designed for use on practical courses,
where the participants are required to put theory into practice, by designing and
constructing, working circuits, to meet with the requirements of typical industrial
applications.
They are progressive from very simple through to more complex and should cover
the needs of most pneumatic courses.
The circuits contained within the solutions are designed in such a way that they can
be constructed from equipment widely available on the market and are not intended
to be manufacturer specific.
IMPORTANT!!
At the time of production an International standard (I.S.O. 5599) exists, this standard
covers, amongst other things, the port labelling of 5 port valves, as follows: -
Supply port - 1
Output ports - 2, 4
Exhaust ports - 3, 5
Signal (pilot) ports - 12, 14
There is no standard (at time of production of these exercises) for the other types of
valves available in pneumatics but most manufacturers have adopted the above
system for their complete range, we have therefore used this system for these
exercises.
Suggestions and recommendations for improvements would be welcomed by the

authors, for possible introduction into future versions.

Pneumatics Level 1 Exercises
1 Assembly Fixture
2 Date Stamping of Product
3 Bending Fixture
4 Panel Removal from a Jig
5 Product Separation
6 Foundry Ladle Control
7 Barrier Control
8 Component Test Machine
9 Coldroom Door Control

10 Roof Ventilator Control
11 Product Sorting
12 Machine Feed
13 Product Cleansing
14 Hopper Door Control
15 Clamping Fixture
16 Blister Pack Assembly
17 Conveyor Selection
18 Lift and Transfer Station
19 Embossing Machine

Exercise: Assembly Fixture
Splined shafts are to be assembled into bushes, the assembly requires a press fit.
The shafts are placed manually into the bush (on a tapered start) a push button is
then actuated to extend a single acting cylinder, through a linkage, as the cylinder
extends the shaft is pressed home. The cylinder is to retract as soon as the push
button is released.
Design a circuit to meet these requirements.

Solution: Assembly Fixture
The push button valve controlling the single acting cylinder is of the 3/2 way, normally
closed (N/C) type. In the at rest condition, the air supply to the valve is closed (port
1), the output (port 2), which is connected to the cylinder, is open to exhaust (port 3),
thereby allowing the cylinder to be retracted, due to the internal spring.
Upon operation of the push button, the supply (1) is connected to the output (2) and
the exhaust is closed (3), this allows compressed air to travel into the cylinder, which
will then extend. Immediately the push button is released, it reverts to its initial
position, the air supply is closed (1) and the air in the cylinder is open to exhaust, the
cylinder is now free to retract.

Questions: Assembly Fixture
1. Draw the symbol for a single acting cylinder, with spring return, according
to ISO 1219-1:
2. List two disadvantages of a single acting spring return cylinder:

3. Label the ports on the valve below, using the number system:
4. Convert the following pressures as required:
a) 6 Bar = PSI
b) 72.5 PSI = Bar

Answers: Assembly Fixture
1. Draw the symbol for a single acting cylinder, with spring return, according
to ISO 1219-1:
2. List two disadvantages of a single acting spring return cylinder:
Can only be used to do work in one direction of travel (that controlled

by compressed air).
Increased overall length due to the space required for the

compressed spring when the piston is extended.
Limited sizes available (stroke and bore) on standard units often the
maximum bore available is 100mm and maximum stroke is also

100mm (although specials are available from some companies but at
considerable premiums on price).
Unit cost is usually higher than double acting cylinder of same bore
and stroke, due to extra materials used (spring, etc), extra assembly
operations required, lower volume manufacture, etc.
4. Convert the following pressures as required:
a) 6 Bar = 87 PSI
b) 72.5 PSI = 5 Bar

Exercise: Date Stamping of Product
Products are to be date stamped (e.g. sell by date on foodstuffs), they are then
packed into cartons, and the cartons themselves are also to be date stamped on the
flap. The date stamp is fitted to the end of a linkage, via a fulcrum pin, this linkage
comes into contact with the carton flap when a double acting cylinder extends. The
signal to start this operation is generated by means of a push button.

Solution: Date Stamping of Product
The cylinder is retracted when the circuit is at rest. When the push button is not
operated, the air supply will flow from the input port 1, to output port 2, of the 5/2 way
valve and on to the front chamber of the cylinder. The rear chamber of the cylinder is
connected to the output port 4 of the 5/2 way valve, which at this time is open to
exhaust port 5. The cylinder is therefore held retracted under air pressure. Upon
operation of the push button the 5/2 way valve switches to its other position and the
connections (internally within the valve) change so that the supply air is now passed
through to the output 4 and output 2 is connected to exhaust port 3, the air pressure
is thereby placed onto the rear chamber of the cylinder, with the front chamber open
to exhaust, the cylinder will then extend and remain extended until the push button is
released. When the push button is released the cylinder will retract, due to the 5/2
way valve being reset (by the internal spring) to the condition as drawn (air pressure
to front of cylinder, rear exhausted).

Questions: Date Stamping of Product
1. Draw the symbol for a double acting cylinder, with spring return, according
to ISO 1219-1:
3. List three other ways of operating a 5/2 way directional control valve:
1)
2)
3) ...
4. Does a double acting cylinder deliver a greater force on the extend or

retract stroke and why ?

Answers: Date Stamping of Product
1. Draw the symbol for a double acting cylinder, with spring return, according
to ISO 1219-1:
3. List three other ways of operating a 5/2 way directional control valve:
1) Foot pedal
2) Lever
3) Lever with detent
4) Air pilot
5) Solenoid (direct)
6) Solenoid (indirect, with air pilot)
4. Does a double acting cylinder deliver a greater force on the extend or

retract stroke and why ?
On the extend stroke due to force being developed by means of

applying pressure to an area and on the extend stroke the pressure is
applied to a greater area (the full face of the piston).

Exercise: Bending Fixture
Strip steel is to be bent to form brackets, the strip is placed into a fixture and is bent
by a single acting cylinder. For the cylinder to bend the steel a certain momentum is
required during its extend stroke, this can only be achieved, if the directional control
valve, controlling the cylinder, is of sufficient size to allow the required amount of
compressed air to flow to the cylinder. The start signal is generated by means of a
push button, which is to be situated at least five (5) metres away from the fixture.
The cylinder bore is to be 150mm and its stroke is to be 100mm.

Solution: Bending Fixture
The push button valve and the pilot valve are both of the normally closed (N/C) type,
supply port (1) is closed and output (2) is open to exhaust (3). The signal line (12) to
the pilot valve is therefore non-pressurised, when the circuit is at rest, this allows the
cylinder to retract, under spring force.
Upon operation of the push button the air supply is passed through the push button
valve (1 to 2) and the signal line is then pressurised, once the pressure at port (12) of
the pilot valve is sufficient to overcome the inbuilt spring this valve will switch, to an
open condition, the air supply now passes from 1 to 2 of this valve and then on to the
cylinder, which extends. Immediately the push button is released, it reverts to its
initial condition and the signal line is exhausted (through port 3), this allows the pilot
valve to revert to its initial position, once this has occurred the cylinder is free to
exhaust and retract.

Questions: Bending Fixture
1. What does the number 12 on the 3/2 way pilot operated valve represent ?
2. The black arrows drawn inside the squares of the 3/2 way valve symbols
indicate what ?

3. Draw the simplified symbol (to ISO 1219-1) for an Air Service Unit:
4. The single acting cylinder is fitted with a breather on the spring side, why ?

Answers: Bending Fixture
1. What does the number 12 on the 3/2 way pilot operated valve represent ?
The number identifies a pilot port, when a signal is applied to this

port the valve will switch to connect the supply port (1) with the
output port (2).
2. The black arrows drawn inside the squares of the 3/2 way valve symbols
indicate what ?
The direction which air is allowed to flow through the valve.
3. Draw the simplified symbol (to ISO 1219-1) for an Air Service Unit:
4. The single acting cylinder is fitted with a breather on the spring side, why ?
Without the breather the piston would not fully extend, due to the air
in the front chamber being trapped and as the piston extends this air
would then become pressurized. With the breather the air is allowed
to escape and then when the piston retracts air will be sucked into
the front chamber via the breather.

Exercise: Panel Removal from a Jig
A sheet metal panel is placed in a jig, while an operation is carried out upon it. Once
the operation is complete the panel is to be lifted clear of the jig, so that the operator
can remove it, with ease. The mechanism used to lift the panel is to be a single
acting cylinder, which is to be controlled by means of a foot pedal or push button,
(either or both actuated will result in the cylinder extending).

Solution: Panel Removal from a Jig
When either the foot pedal or the push button is operated, air will pass via the shuttle
valve to the cylinder, which will then extend. When both the foot pedal and push
button valves are released the cylinder is open to exhaust and will therefore retract.
A shuttle valve is necessary, as otherwise the air from the output of either the foot
pedal or push button would travel through to the exhaust port of the opposite valve,
this would mean the cylinder would not extend, as required in this case.

Questions: Panel Removal from a Jig
1. Draw the symbol, to ISO 1219-1, for a shuttle valve :
2. Show using a truth table its function :
1 1 2
3. Why cant check valves, as shown below, be used in place of the shuttle
valve ?
4.
5. Complete the symbol below for the shuttle valve and state whether there
will be an output available at 2, if yes, then what pressure would that
output be ?

Answers: Panel Removal from a Jig
1. Draw the symbol, to ISO 1219-1, for a shuttle valve :
2. Show using a truth table its function :
1 1 2
0 0 0
1 0 1
0 1 1
1 1 1
3. Why cant check valves, as shown below, be used in place of the shuttle
valve ?
If check valves were used as per the diagram the cylinder would
never retract after its first extend movement, due to the check valves
would lock the air into the rear chamber of the cylinder.
4. Complete the symbol below for the shuttle valve and state whether there
will be an output available at 2, if yes, then what pressure would that
output be ?
There will be an output at 2 in this condition (both signals present)

the pressure available will be the higher of the two inputs and in this
case would therefore be 6 bar.

Exercise: Product Separation
Products (e.g. parcels) are to be separated in a distribution warehouse, where the

incoming products arrive on one conveyor and are to be dispatched to either of two
output conveyors. The required output conveyor is selected by a double acting
cylinder, which in turn is controlled by an operator. The operator has in front of him,
two (2) push buttons (separate units), when one push button is actuated, the cylinder
will extend and remain extended, even when this push button is released. To retract
the cylinder the other push button must be actuated, again the cylinder will remain
retracted, even when the push button is released, until such time that the first
(extend) push button is actuated again.

Solution: Product Separation
In the at rest condition, both push button valves are closed and therefore there are no
signals at ports 14 or 12 of the directional control valve 1.3, the air supply is therefore
passing from the supply port 1 to output port 2 of this valve and then into the front
chamber of the cylinder, keeping it in a retracted position. To extend the cylinder the
push button valve 1.1 must be operated, this allows air into the signal line and to port
14 of the valve 1.3, this valve will then switch and supply air to port 4 and then to the
rear chamber of the cylinder, the cylinder then extends, with the air from the front
chamber flowing to exhaust via ports 2 and 3 of the valve 1.3. At this stage the push
button valve (1.1) can be released and the valve 1.3 will remain in this position (due
to it being a memory type valve). To retract the cylinder the push button valve 1.2
must be operated, this applies a signal to port 12 of valve 1.3, which switches the
valve back to its original position and air flows from the supply port 1 to the output
port 2 and to the front chamber of the cylinder, with the rear chamber of the cylinder
open to exhaust, via ports 4 and 5 of the valve 1.3, the cylinder will now retract.

Questions: Product Separation
1. Describe, using standard pneumatic terminology, the valve shown below:
....
...
2. With the valve shown what is the effect of:
a) Placing a signal (pressure) on port 14

b) Placing a signal (pressure) on port 12
3. Directional control valves are listed by manufacturers as , , , etc,

what do these figures refer to ?
4. Do the push button valves used in the solution need to be of the same size
as the cylinder control valve, if not why ?

Answers: Product Separation
1. Describe, using standard pneumatic terminology, the valve shown below:
5/2 way directional control valve, double pilot actuated, (also

sometimes called a 5/2 way memory, 5/2 way bi-stable, or a 5/2 way
impulse valve).
2. With the valve shown what is the effect of:
a) Placing a signal (pressure) on port 14
The valve will switch to the left hand square and the supply port (1)
will be connected to the output port (4).
b) Placing a signal (pressure) on port 12
The valve will switch to the condition as shown and the supply port
(1) will be connected to the output port (2).
3. Directional control valves are listed by manufacturers as , , , etc,

what do these figures refer to ?
The size of the thread at the port of the valve, for the European
market these sizes are BSP (British Standard Pipe thread), which are
the standard threads. With the exception of M5 (5mm) all other
standard threads sizes are BSP. For the American market imperial
sizes are NPT (National Pipe Thread).
4. Do the push button valves used in the solution need to be of the same size
as the cylinder control valve, if not why ?
The push button valves used can be of a smaller size than the
cylinder control valve, this is because they are only used to apply
signals to the control valve and large volumes of air are not required
for this function, as the air is not travelling through the valve but into
an enclosed chamber and only sufficient air to switch the valve is
necessary.

Exercise: Foundry Ladle Control
In a foundry, molten metal is to be poured from a ladle, a double acting cylinder is

used to lift (tilt) the ladle. To extend the cylinder a push button must be actuated, to
retract the cylinder a second push button must be actuated. The cylinder will remain
in the last position that it is sent too, until the opposite push button is actuated.
Both the cylinder extend and retract speeds are to be slow and adjustable
(independent of each other).

Solution: Foundry Ladle Control
Upon operation of the push button (1.1) a signal is placed upon the directional control
valve 1.3 (at port 14), this causes this valve to switch and pass air from port 1
(supply) to port 4 (output feeding rear chamber of the cylinder). Air passes from the
output of valve 1.3 to the cylinder via the by-pass and check valve of the
throttle/check valve and enters the cylinder at a non-restricted rate. The cylinder will
then extend, as it does the air in the front chamber travels through a throttle and can
therefore be controlled, thereby slowing down the extend speed (flow and therefore
speed is adjustable).
When the valve 1.3 is reversed, by operation of the push button 1.2, air flows into the
front chamber of the cylinder via the by-pass (the check valve will allow air flow in this
direction) at a non-restricted rate. However the air from the rear chamber of the
cylinder flows through a throttle on its way to port 4 of valve 1.3 and therefore the
retract speed is slower than normal and adjustable.
Throttle/check valves are available as in-line units or as units that can be fitted
directly into the cylinder port. The closer that the valve is placed to the cylinder the
better the control will be.

Questions: Foundry Ladle Control
1. Draw the symbol, to ISO 1219-1, for a throttle/check (one-way flow control)
valve:
2. In the circuit below complete the symbol for the throttle/check valve so that
the cylinder will extend slower than normal:
3. Draw a circuit, using ISO 1219-1 symbols, showing how throttle/check

valves can be used, so that a single acting cylinder can extend and retract
slowly, with both directions of travel being independently adjustable:
4. With a double acting cylinder of a bore size of 25mm, or greater, would it

be better to slow down the piston speed with supply or exhaust air
throttling and why ?

Answers: Foundry Ladle Control
1. Draw the symbol, to ISO 1219-1, for a throttle/check (one-way flow control)
valve:
2. In the circuit below complete the symbol for the throttle/check valve so that
the cylinder will extend slower than normal:
3. Draw a circuit, using ISO 1219-1 symbols, showing how throttle/check

valves can be used, so that a single acting cylinder can extend and retract
slowly, with both directions of travel being independently adjustable:
4. With a double acting cylinder of a bore size of 25mm, or greater, would it

be better to slow down the piston speed with supply or exhaust air
throttling and why ?
It would be better to control the cylinder speed with exhaust air

throttling, this is due to the air would be controlled on its exit from
the cylinder and would have a braking effect on the cylinder
movement. If the cylinder is controlled by supply air throttling a
common problem is the cylinder will tend to run-away in an
uncontrolled manner, resulting in a jerky movement.

Exercise: Barrier Control
An entry/exit barrier at a factory gate is to be controlled by means of a double acting

cylinder. The barrier is raised and lowered by security personnel, situated in the
adjacent gatehouse. To raise the barrier a push button must be actuated,
immediately the barrier starts to move this push button can be released and the
barrier will continue to rise until it is at its maximum height, where it will stay, until a
second (totally separate) push button is actuated. Once the second push button is
actuated the barrier will lower, again as soon as the barrier starts to move the push
button can be released and the barrier will continue to lower, until it reaches its
lowest position, where it will remain, until the first (raise) push button is actuated once
again. The barrier is to rise and fall slowly (cylinder extends and retracts slowly).
It should be noted that the cylinder is in the extended position when the circuit is at
rest (barrier closed).

Solution: Barrier Control
When the barrier is down the cylinder is extended. To raise the barrier the push
button marked barrier up is operated, this places a signal upon port 12 of the
directional control valve, which switches and places air on the front port of the
cylinder (via the by pass and check valve of the throttle/check valve and therefore at
a non-restricted rate) and the cylinder retracts, raising the barrier. As the cylinder
retracts the air from the rear chamber travels through the throttle of a throttle/check
valve, this air flow is adjustable, and the cylinder retract speed is therefore slower
than normal and adjustable (smooth movement of the barrier). Once the barrier
reaches it upper position (cylinder fully retracted) it will remain in this position, until
the push button marked barrier down is operated.
Upon operation of the push button marked barrier down a signal is placed upon port
14 of the directional control valve and this valve switches (providing there is no signal
at port 12) passing air to the rear chamber of the cylinder, via the by pass and check
valve (therefore at a non-restricted rate). The front chamber of the cylinder exhausts
via the throttle of the throttle/check valve and therefore the barrier lowers at a slow
(and adjustable) speed, smooth operation is thereby achieved. The barrier reaches
its lower position and remains there until the barrier up push button is operated
again.

Questions: Barrier Control
1. Why can a throttle valve not be used in the supply to the 5/2 way control
valve instead of the throttle/check valves ?
....
...
2. Show and alternative solution using a 5/2 way lever valve (with detent)
instead of the two 3/2 way push buttons, to give the same result:
3. Where should the throttle/check valves be situated in the circuit for the best
control of the cylinder ?
4. Which throttle/check valve is controlling the barrier lowering speed

(cylinder extending) ?

Answers: Barrier Control
1. Why can a throttle valve not be used in the supply to the 5/2 way control
valve instead of the throttle/check valves ?
If a throttle valve was used on the control valve supply, when it was
adjusted the speed of cylinder movement in both directions would be
affected, this is undesirable. It is beneficial to have independent
control of the cylinder speed in both directions of travel.
2. Show and alternative solution using a 5/2 way lever valve (with detent)
instead of the two 3/2 way push buttons, to give the same result:
3. Where should the throttle/check valves be situated in the circuit for the best
control of the cylinder ?
For best control the throttle/check valves should be situated as close

as possible to the ports of the cylinder, this means they are
controlling only the air in the cylinder and not the air in the
associated valves and pipework, thereby ensuring a better control.
4. Which throttle/check valve is controlling the barrier lowering speed

(cylinder extending) ?
The throttle/check valve shown on the right hand side of the circuit
diagram (the unit fitted in the front port of the cylinder).

Exercise: Component Test Machine
Chairs are to be tested for strength and durability, this test is to be carried out by
using a double acting cylinder, which once the system is switched ON is to
continuously cycle (extend and then immediately retract, repeatedly), until it is
switched OFF. When the system is switched off, the cylinder must stop in the
retracted position, irrelevant to its position at that time. The number of cycles
completed is to be counted, so that the life expectancy of the chair before anticipated
failures can be established.

Solution: Component Test Machine
When the circuit is at rest, the cylinder is retracted and therefore roller valve 1.2 is
actuated. Upon operation of the ON/OFF valve (1.1) a signal is sent to port 14 of the
valve 1.4, this valve is then switched and the air is passed through the valve to the
rear chamber of the cylinder, which will then extend. As the cylinder extends the
roller valve 1.2 is released, this causes it to reset to its normal condition, which is
closed, this blocks the air from the ON/OFF valve and also allows the signal from port
14 to travel to exhaust. Once the cylinder reaches its fully extended position the
roller valve 1.3 is actuated, this sends a signal to port 12 of the valve 1.4, which
switches to the position as shown and passes air to the front chamber of the cylinder,
which will then retract. As the cylinder retracts it releases valve 1.3 and at its fully
retracted position actuates valve 1.2, the cycle is then repeated. The circuit will keep
cycling until the ON/OFF valve is reselected (turned off), this takes the supply away
from the roller valve 1.2 and the cylinder will therefore stop in the retracted position,
no matter where it is at the time the ON/OFF valve is selected to its off position (due
to the fact that it is the extend signal that is eliminated).
Each time that the extend position roller valve (1.3) is actuated a signal is also placed
upon the counter (port Z) and therefore each cycle of the cylinder is counted. The
counter can be reset by means of the push button marked reset, which sends a
signal to port Y of the counter.

Questions: Component Test Machine
1. What does the symbol below represent ?
....
...
2. How do these valves differ ?

a. b.
3. Name two types of pneumatic counter:
1) ..
2) ..
4. How are pneumatic counters generally reset ?

Answers: Component Test Machine
1. What does the symbol below represent ?
This symbol represents a 3/2 way directional control valve, roller

actuated, spring return, normally closed type. The symbol is drawn
to represent the valve being operated and is therefore shown in its
switched (operated) condition.
2. How do these valves differ ?
a. b.
Both symbols represent 3/2 way directional control valves,
a) is operated by means of a hand lever, with spring return
b) is operated by means of a hand lever, with detent (both positions

have to be manually selected).
3. Name two types of pneumatic counter:
1) Predetermined counter (a number is set on the counter and it

counts down from this number to zero).
2) Totalising counter (the counter starts at zero and simply counts

up).
4. How are pneumatic counters generally reset ?
By means of a signal (pneumatic) placed on the signal port of the

counter, a manual reset button is also generally incorporated.

Exercise: Coldroom Door Control
The door on a coldroom store (e.g. supermarket) is to remain closed (not locked) at
all times, other than when a person is passing through it. When the door is
approached from either side there are two (2) push buttons on the wall, adjacent to
the door, one marked Open the other marked Close (therefore four (4) push
buttons in total). A person wishing to enter or leave the coldroom may open the door
by actuating either of the Open push buttons, once through the door they will then
actuate the Close push button.
It should be noted that when the system is at rest (door closed) the cylinder is in an
extended condition.

Solution: Coldroom Door Control
When the circuit is at rest the cylinder is extended, which keeps the door closed. If
either push button 1.3 or 1.4 are operated a signal is sent via the shuttle valve 1.6 to
port 12 of the directional control valve 1.7, this valve switches and the cylinder will
retract (door opens). The push buttons 1.1 and 1.2 are linked via the shuttle valve
1.5, such that if either of these push buttons are operated a signal is placed at port
14 of the valve 1.7 and this valve is then switched, extending the cylinder (door
closes).
Push buttons 1.1 and 1.2 are on opposite side of the wall in this exercise as are push
buttons 1.3 and 1.4.

Questions: Coldroom Door Control
1. What is the function of a shuttle valve ?
....
...
...
2. Where are shuttle valves required ?

...
3. Can a TEE be used instead of a shuttle valve, if not, why ?
...
4. Give another name for a shuttle valve:

Answers: Coldroom Door Control
1. What is the function of a shuttle valve ?
A shuttle valve is a double check valve but with only one seal (all
contained within one unit), it will allow either (or both) of two inputs
to become an output and at the same time close off the other input
path, so that it is not possible for the air to travel to exhaust. As it
will allow either or both inputs to become an output it is often called
an OR gate.
2. Where are shuttle valves required ?
Shuttle valves are required wherever two input signal lines join and
an output signal is required when either input signal is present.
3. Can a TEE be used instead of a shuttle valve, if not, why ?

A tee cannot be used to replace a shuttle valve, if it was the air from
either signal line would exhaust along the other signal line (air will
always take the path with the least resistance), the check valve
function within the shuttle valve avoids this problem.
4. Give another name for a shuttle valve:
OR gate.

Exercise: Roof Ventilator Control
A roof ventilator is to be controlled by means of a pneumatic cylinder, this cylinder is

to extend (window OPEN) when any one of three specially separated push buttons
are operated, the cylinder is to retract (window CLOSE) when a fourth push button is
operated. If when, either, extending or retracting, the relevant push button/s is/are
released, then the cylinder is to stop in the position, that it is in, at that time, therefore
giving the facility of inching the cylinder and having the window partially open (by any
amount). For security reasons the window will always be closed in the at rest
condition.
Two (2) separate solutions are required for this exercise: -
1) Utilising a double acting cylinder

2) Utilising a single acting cylinder and four (4) other components only

Solution: Roof Ventilator Control
The cylinder in this exercise is required to perform three functions extend, retract
and stop (anywhere within its stroke length) and therefore with a double acting
cylinder controlled by a 5 port valve, the valve requires 3 positions (one for each
cylinder function). With this type of valve, the neutral (default) position is selected
when no switching signals are present at the valve (by means of springs, either
mechanical or air on both ends of the valve spool). When the push button 1.1 is
operated a signal will travel via the shuttle valve 1.6 to the 5/3 way valve 1.7 (port 14)
this valve switches and air is allowed into the rear chamber of the cylinder, which will
extend, until the push button is released, the signal at port 14 is then removed and
the springs will centre the 5/3 way valve, to its neutral position of all ports blocked, no
air is allowed to pass across the valve and the cylinder is therefore held in this
position by the pressure that is trapped in both the rear and front chambers. Upon
operation of push button 1.2 or 1.3, the same thing will happen except that the output
of these push buttons must also travel through the second shuttle valve (1.5), before
reaching the shuttle valve 1.6.
When the retract push button 1.4 is operated there is a signal placed upon port 12 of
the 5/3 way valve, this causes it to switch and place air to the front chamber of the
cylinder, which then retracts until the push button 1.4 is released and the signal is
lost from port 12 allowing the valve to revert to its neutral position, of all ports blocked
and the cylinder will again stop at this point (wherever in its stroke it happens to be at
the time).

Solution: Roof Ventilator Control
Solution utilising single acting cylinder and 2/2 way valves.

When any of the push buttons connected to the mains supply are operated, air
passes to the cylinder and when all the push buttons are released their springs hold
them in a closed condition, this traps any air in the system between the valves and
the cylinder (due to all the valves being of the 2/2 way type). To retract the cylinder
the fourth push button is operated and the valve is opened allowing the air to travel
from the cylinder to exhaust.
Solution utilising single acting cylinder and 3/2 way valves.

This solution gives the same result as the version utilising 2/2 way valves but all the
exhaust ports of the 3/2 way valves that are connected to the mains air supply are
connected to the supply port of the fourth (retract) push button, once this push button
is operated the air is allowed to exhaust from the system and the cylinder will then
retract under spring force.
Note:
In both versions all joints must be leakage free, to avoid cylinder creep. For
this reason these are not preferred solutions for this application.

Questions: Roof Ventilator Control
1. How is the valve represented by the symbol below described ?
....
...
2. How is the centre (neutral) condition selected ?

3. How do these valves represented by the symbols below differ ?
a. b.
4. What could be a potential problem in the 2/2 way valve solution which
results in it being an unpopular solution for practical purposes ?

Answers: Roof Ventilator Control
1. How is the valve represented by the symbol below described ?
The symbol represents a 5/3 way double pilot actuated directional

control valve with centre (neutral) condition all ports closed.
2. How is the centre (neutral) condition selected ?
The centre condition is automatically selected when neither of the

signals are present to switch the valve.
3. How do these valves represented by the symbols below differ ?
a. b.
Both are 3/2 way push button operated, spring return valves but they
differ because
a) is of the normally closed type
and
b) is of the normally open type.
4. What could be a potential problem in the 2/2 way valve solution which
results in it being an unpopular solution for practical purposes ?
The solution utilising 2/2 way valves relies on a totally leak free
system for it to function correctly. If there are any leaks (no matter
how slight) then there will be movement on the cylinder, this would
obviously be undesirable and in some applications could be
dangerous. With the number of joints in the system it would be
difficult to guarantee a totally leak free system especially if the joints
are opened and remade after initial installation.

Exercise: Product Sorting
Components arrive on a conveyor and are to be pushed into a power press by

means of a double acting cylinder. There are two (2) push buttons and the cylinder is
only to extend when both push buttons are actuated, (if only one (1) push button is
actuated, the cylinder is to remain retracted). Once the cylinder starts to extend, if
either or both push buttons are released, the cylinder is to immediately retract to its
start condition.

Solution: Product Sorting
This circuit utilises a two pressure valve 1.3 and this type of valve will only allow an
output at port 2 when it receives input signals at both inputs. Therefore both push
buttons 1.1 and 1.2 MUST be operated before the two pressure valve will pass a
signal through to the 5/2 way valve 1.4. Once a signal is received, at port 14, it
causes valve 1.4 to switch and this in turn will extend the cylinder. Immediately
either push button is released the output from the two pressure valve is lost
(because only one input is present), this removes the signal from port 14 of the valve
1.4, which resets by means of the spring. As soon as the valve 1.4 resets the air
supply to the cylinder is reversed, causing it to retract.

Questions: Product Sorting
1. Draw the symbol to ISO 1219-1 for a two pressure valve:
2. Show using a truth table its function:
1 1 2
3. Draw a circuit using ISO 1219-1 symbols where push buttons must be
operated to get an output signal but without the use of a two pressure
valve:
4. Complete the symbol below for the two pressure valve and state whether
there will be an output available at 2, if yes then what pressure would that
be ?

Answers: Product Sorting
1. Draw the symbol to ISO 1219-1 for a two pressure valve:
2. Show using a truth table its function:
1 1 2
0 0 0
1 0 0
0 1 0
1 1 1
3. Draw a circuit using ISO 1219-1 symbols where push buttons must be
operated to get an output signal but without the use of a two pressure
valve:
4. Complete the symbol below for the two pressure valve and state whether
there will be an output available at 2, if yes then what pressure would that
be ?
There will be an output at 2 in this condition (both signals present)

the pressure available will be the lower of the two inputs in this case
3 bar.

Exercise: Machine Feed
Components are loaded, manually, into a gravity feed magazine, these components
are then fed, one at a time into a machine. For the cylinder to extend the start
conditions must be met, these conditions are: -
There must be a component in the magazine

The cylinder must be fully retracted
Two (separate) push buttons must be actuated
Upon reaching the fully extended (outstroked) position the cylinder is to be

automatically retracted (instroked) to its start position.
To repeat the operation the start conditions must again be achieved.

Solution: Machine Feed
When the circuit is at rest the cylinder is retracted and therefore the roller valve 1.6
is actuated. To start the cycle a component must first be placed in the machine, this
is registered by the plunger valve 1.5. Only when both push buttons 1.1 and 1.2 are
operated will the two pressure valve 1.4 have both inputs, thereby giving an output at
2, once this output is present it will travel through valves 1.5 and 1.6 to the signal port
(14) of valve 1.7 which will then switch, placing air onto the rear of the cylinder, which
in turn extends. As the cylinder extends it releases the roller valve 1.6, which breaks
the signal feed to the valve 1.7, once the cylinder reaches its fully extended position
the roller valve 1.3 is actuated and this places a signal onto the valve 1.7 (at port 12),
this switches the valve back again to its original position (as drawn) and puts air into
the front of the cylinder, the cylinder then retracts, as it does so the first thing to
happen is the for the roller valve 1.3 to be released, this exhausts the signal from port
12 of the valve 1.7. When the cylinder is fully retracted the roller valve 1.6 is once
again actuated and the circuit is ready for the next operation.

Questions: Machine Feed
1. What logic function is provided in the circuit by valves 1,5 and 1,6 ?
....
...
2. If the circuit was run on continuous cycle, where would the cylinder stop
when the magazine runs out of components and why ?

3. If the circuit was to run when either 1,1 or 1,2 were operated instead of
both 1,1 and 1,2 what modifications would be required ?
4. What disadvantage would the circuit have if all the valves 1,1, 1,2, 1,5 and
1,6 were placed in series ?

Answers: Machine Feed
1. What logic function is provided in the circuit by valves 1,5 and 1,6 ?
AND function.
2. If the circuit was run on continuous cycle, where would the cylinder stop
when the magazine runs out of components and why ?
The cylinder would stop in the retracted position due to the magazine
(component) register is in the signal line that generates an extend
signal, the retract signal would still be allowed to complete its
function.
3. If the circuit was to run when either 1,1 or 1,2 were operated instead of
both 1,1 and 1,2 what modifications would be required ?
The two pressure (AND) valve (1,4) would have to be changed for a
shuttle (OR) valve.
4. What disadvantage would the circuit have if all the valves 1,1, 1,2, 1,5 and
1,6 were placed in series ?
The signal feeding port 14 of valve 1,7 is now going through four
valves, which all get their supply from the one point and therefore
there is a distinct possibility that the strength of this signal when it
reaches valve 1,7 will only be very weak.
With the solution shown there is a better possibility of a strong signal

at valve 1,7 due to there being two main supplies and each one
travelling trough three valves. This is especially relevant where long
runs of pipe (or tubing) are to be utilised.

Exercise: Product Cleansing
Components are to be washed before assembly, they are placed into a container,
which is to be dipped in and out of the cleansing fluid. Once the START push
button has been actuated the cylinder is to continuously cycle, until such time that the
STOP push button is actuated (two (2) separate push buttons are required). The
container must not meet the cleansing fluid with a hard impact (danger of splashes!).
When the stop button is actuated, the cylinder must stop in the retracted (container
UP) position.

Solution: Product Cleansing
Upon operation of the start push button (1.1) a signal is placed upon valve 1.3
selecting it to an open position and mains air is then passed to the roller valve 1.5,
which is sensing that the cylinder is retracted. Providing this valve (1.5) is actuated
the signal then passes to the valve 1.6 (port 14), this valve is then switched and the
air is passed to the rear of the cylinder, which then extends. Once the cylinder
reaches its forward end position (fully extended) the roller valve 1.4 is actuated and a
signal is now placed upon port 12 of the valve 1.6. When the cylinder extended it
released roller valve 1.5 and therefore the signal has been removed from port 14 of
the valve 1.6, the signal at port 12 will thereby be allowed to switch the valve (1.6)
and air is passed through to the front of the cylinder causing it to retract, as it retracts
the roller valve 1.4 is released and the signal is then exhausted from port 12 of the
valve 1.6. When the cylinder reaches its fully retracted position it actuates the roller
valve 1.5 and the sequence starts again. The cycle keeps repeating until such time
that the stop push button is operated, this applies a signal to the valve 1.3 which is
switched to the original position (as drawn), which blocks the mains air supply and
opens the output to exhaust. As this is in the line generating the extend signal the
cylinder will stop in the retracted position.

Questions: Product Cleansing
1. If a 3/2 way valve was not available for use at position 1,3 show how a 5/2
way valve could be used as a substitute:
2. Show how the cylinder speed can be effected by adjusting the exhaust flow
through the valve, instead of the air flow from the cylinder:
3. In the answer to 2 above, what is the name for the component being used
as an option to the throttle/check valve ?
4. With this application it may be difficult to mount the roller valves at the front
of the cylinder, therefore show (with a circuit using ISO 1219-1 symbols)
how a double acting cylinder with through rod can be used marking the
diagram to show where the roller valves are to be fitted:

Answers: Product Cleansing
1. If a 3/2 way valve was not available for use at position 1,3 show how a 5/2
way valve could be used as a substitute:
2. Show how the cylinder speed can be effected by adjusting the exhaust flow
through the valve, instead of the air flow from the cylinder:
3. In the answer to 2 above, what is the name for the component being used
as an option to the throttle/check valve ?
(Exhaust Port) Throttle Valve.
4. With this application it may be difficult to mount the roller valves at the front
of the cylinder, therefore show (with a circuit using ISO 1219-1 symbols)
how a double acting cylinder with through rod can be used marking the
diagram to show where the roller valves are to be fitted:

Exercise: Hopper Door Control
Loose product (e.g. grain) is to be loaded into a container. To open the hopper door
a container must first be present (checked by means of a limit switch) and either of
two (2) push buttons actuated, the hopper door is to remain open for five (5) seconds
only, before closing again. The time cycle is to commence from when the cylinder
starts to extend.

Solution: Hopper Door Control
Before the circuit can start a container must be placed below the hopper door, once
this has been done and is registered by the valve 1.5, the cycle can be started by
operation of either of the push buttons 1.1 or 1.2. A pilot signal is sent from the
respective push button via the shuttle valve (1.3) and the container register (1.5) to
port 14 of valve 1.6, this valve switches and the cylinder will extend. While the
cylinder is in the extend mode the air pressure is supplied to its rear chamber. A
signal is taken from the feed line to the cylinder and placed upon the signal port (12)
of the timer valve (1.4), thus the time delay starts from when the cylinder starts to
extend. Once the time delay has elapsed the timer valve 1.4 switches to its open
condition and a signal is then passed through to valve 1.6 (port 12), this valve
switches to its original condition (as drawn) and the cylinder then retracts, the signal
to the timer valve is removed once the valve 1.6 is switched to retract the cylinder.
This puts the circuit back to its at rest condition, ready for the next cycle.

Questions: Hopper Door Control
1. Draw the full symbol to ISO 1219-1 for a pneumatic timer valve of the
normally open type:
2. When does the timing start in this circuit/exercise ?

3. If the requirement was for the timing to start only after the cylinder has
reached its fully outstroked position what other component is required and
where would it be mounted ?
4. What would be the effect on the set time delay if the system pressure:
a) Drops: .
b) Increases .

Answers: Hopper Door Control
1. Draw the full symbol to ISO 1219-1 for a pneumatic timer valve of the
normally open type:
2. When does the timing start in this circuit/exercise ?
The timing starts from when the directional control valve is switched
to feed air to the rear of the cylinder due to the signal for the timer
valve being taken directly from the feed line of the cylinder.
3. If the requirement was for the timing to start only after the cylinder has
reached its fully outstroked position what other component is required and
where would it be mounted ?
A position register (e.g. roller valve) would be required at the end of

the cylinder stroke the output of this valve would then feed the signal
to the timer, this would ensure that the timing would not start until the
position register was actuated thus ensuring that the cylinder was at
the end of its stroke before a signal was applied to the timer.
4. What would be the effect on the set time delay if the system pressure:
a) Drops: The time delay would be increased over that originally

set.
b) Increases The time delay would decrease from that originally

set.

Exercise: Clamping Fixture
A work piece is to be firmly clamped while it is drilled, the clamp is to be operated by

means of a double acting cylinder. For the cylinder to extend the following conditions
must be met: -
A work piece must be present in the fixture

Either of two (2) push buttons is to be actuated
Once these conditions are met the cylinder will extend, slowly (speed is to be
adjustable).
For safety reasons, during drilling it must not be possible to unclamp the component,
when the drill is returned to its uppermost position the component may be
unclamped, by the actuation of a third push button. The unclamping speed is to be
very fast.

Solution: Clamping Fixture
For the circuit to become operational there must first be a work piece placed in the
fixture, this is then registered by the valve 1.5 once this valve is operated the cycle is
started by either of the clamp push buttons (1.1 or 1.2). When one of the push
buttons is operated the signal is sent via the shuttle valve (1.4) and the work piece
register (1.5) to the valve 1.7 (port 14), this valve switches and the cylinder will
extend and clamp the work piece. Due to the throttle/check (flow control) valve in the
front port of the cylinder the extend speed of the cylinder is slow and adjustable, this
gives better control and less chance of the work piece being moved as the cylinder
clamps it.
For the clamp to be released (cylinder retracted) the drill must first be in the correct
position, registered by the valve 1.6 and then the unclamp push button 1.3 operated.
This will allow a signal to travel via these valves to valve 1.7 (port 12), which switches
and the cylinder then retracts, the retract speed of the cylinder is faster than normal
because of the quick exhaust valve that is fitted in the rear port, allowing the air from
the cylinder to escape directly to atmosphere at this point, instead of through valve
1.7 and the interconnecting pipe work.

Questions: Clamping Fixture
1. Draw the symbol for a quick exhaust valve:
2. What would be the effect if a silencer was inserted in the exhaust port of
the quick exhaust valve and how do manufacturers often overcome this
situation ?
.
3. Where else in the circuit could the workpiece register (1,5) be placed, still
meeting with the original specification and without any detriment to the
application ?
4. Does it make any difference to the result if the valve 1,3 feeds 1,6 or vice
versa and why ?

Answers: Clamping Fixture
1. Draw the symbol for a quick exhaust valve:
2. What would be the effect if a silencer was inserted in the exhaust port of
the quick exhaust valve and how do manufacturers often overcome this
situation ?
The exhaust noise would be reduced but at a sacrifice to the speed at

which the air is exhausted (the silencer acts as a restriction), to
overcome this situation one common method is to have the exhaust
port of the quick exhaust valve one size larger to accommodate a
larger silencer (e.g. On a ported quick exhaust valve the exhaust
port would be 3/8) also longer than standard silencers are
sometimes available (thus increasing the surface area and reducing

the restriction).
3. Where else in the circuit could the workpiece register (1,5) be placed, still
meeting with the original specification and without any detriment to the
application ?
The workpiece register would be placed in the circuit before the push
buttons 1,1 and 1,2 it would be supplied direct from the mains and its
output would feed the supply to the push button valves 1,1 and 1,2.
This would mean that for the cylinder to extend a workpiece must be
present and either of the push buttons can be operated.
4. Does it make any difference to the result if the valve 1,3 feeds 1,6 or vice
versa and why ?
It would make no difference to the operation of the circuit whether 1,3

feeds 1,6 or vice versa due to the valves being in series. However if
the roller was to feed the push button (1,6 feed 1,3) it would mean that
the input of the push button is live at all times that the drill is
registered, in certain applications this could be deemed unsafe.

Exercise: Blister Pack Assembly
Toys are to be heat sealed into blister packs, a double acting cylinder will clamp the
plastic blister to the card backing, while the heat sealing takes place. The cycle is
started by means of a push button, when this is actuated the cylinder is to extend,
slowly, to its forward end position, it will then remain in this position for a period of
five (5) seconds, while the heat sealing takes place. Once the five seconds have
elapsed the cylinder is to retract, rapidly to its initial position.
Additional requirements: -
The cylinder must retract, after the five seconds, even if the push button
has been held down.
For the sequence to start again the cylinder must reach its fully retracted
position and the start button must be actuated again (if the push button is
held down, the cylinder must retract fully and then stop, until the push
button is released and then actuated once again), thus ensuring only one
cycle from one actuation of the push button.

Solution: Blister Pack Assembly

Solution: Blister Pack Assembly
The at rest condition of this circuit is with the cylinder retracted and therefore the
roller valve 1.4 is actuated. When the push button 1.1 is operated, a signal is sent
via valves 1.3 and 1.4 to the valve 1.6 (port 14), this valve then switches and the
cylinder will extend, slowly (due to the throttle/check valve in the front port of the
cylinder). At the forward end position (fully extended) the cylinder strikes the roller
valve 1.2, actuating it and sending a signal to the timer valve 1.5, which itself
switches after the set time delay of five (5) seconds has elapsed, a signal is then
placed upon valve 1.6 at port 12, this valve switches back to the state shown and the
cylinder is retracted, rapidly (due to the quick exhaust valve).
Roller valve 1.4 has been introduced into the circuit to meet with the first additional
requirement, when the cylinder extends this valve is released and reverts to its
normal condition (closed), which eliminates the signal from the push button to port 14
of valve 1.6, only when the cylinder has fully retracted is this valve actuated again.
Therefore the cylinder will retract, even if the push button is held down, however on
reaching its fully retracted (instroke) position it will actuate the valve again and the
cylinder will then extend, this sequence and action will then be repeated for as long
as the push button is held down.
The second additional requirement is to eliminate the possibility of repeat cycling

and can be achieved by means of the normally open timer valve (1.3). This valve will
only come into use if the push button is held down for a duration of time. Due to this
valve being a normally open type the signal from the push button will pass directly
through the timer, the push button is also sending a signal to this timer (port 10) and
therefore if the push button is held down long enough the timer will be actuated and
will switch, to a closed condition, blocking the signal from the push button at port 1
and exhausting the output line from port 2 through to port 3. To reset the timer valve
to its open condition the push button must be released to allow the signal to be
exhausted from its pilot port.
NOTE!!
It will not always be necessary to install a timer as the valve 1.3, if the valve 1.6 being
a double pilot valve will switch with a lower pressure at port 14 than the pressure
required at port 10 to switch valve 1.3 (because of its spring), then a 3/2 way pilot
valve is all that is required, thus being a cheaper solution than with a timer valve.

Questions: Blister Pack Assembly
1. How do valves 1,3 and 1,5 differ ?
....
...
2. What is the purpose of valve 1,3 in the circuit ?
3. What would be the effect if any of fitting valve 1,3 downstream of (after)
valve 1,4 ?
4. What would be the effect if any of fitting valve 1,5 upstream of (before)
valve 1,2 ?

Answers: Blister Pack Assembly
1. How do valves 1,3 and 1,5 differ ?
Both valves are timer valves 1,3 is of the normally open type and 1,5
is of the normally closed type.
2. What is the purpose of valve 1,3 in the circuit ?
Valve 1,3 being a normally open timer will close after a time delay
elapses, if the signal is maintained at port Z (10) of this valve for this
signal to be maintained the push button 1,1 is being held down. This
exercise specifically states that if the push button is held down that
the circuit is to complete one cycle and then stop this function is
provided by this timer valve which if switched will stop the start
signal from passing through.
3. What would be the effect if any of fitting valve 1,3 downstream of (after)
valve 1,4 ?
The timer valve would not come into operation due to the signal feed
being removed whenever the roller valve 1,4 was released (cylinder
extending) and therefore the valve 1,3 would be redundant and the
requirement of the circuit stopping after one cycle if the push button
is held down would not be achieved.
4. What would be the effect if any of fitting valve 1,5 upstream of (before)
valve 1,2 ?
The timer valve 1,5 if fitted before the roller valve 1,2 would be
permanently actuated due to its signal coming direct from the mains
supply, this valve would therefore become ineffective and the time
delay function would be lost the cylinder would retract immediately
that it reached the end of its stroke and actuated the roller valve.

Exercise: Conveyor Selection
In the shipping department of a large company, parcels, which arrive on a roller

conveyor, are to be dispatched to one of four different destinations. A separate
output roller conveyor feeds each destination. The selection of the outputs is
achieved by means by means of two double acting cylinders, mounted back to back.
The extend and retract of each cylinder is determined by means of four (4) separate
push buttons, if the cylinders were designated A and B and the push buttons were
designated 1, 2, 3, and 4 then the following conditions should apply: -
Actuation of 1 will extend A and retract B (no matter what their previous
positions).
Actuation of 2 will extend B and retract A (no matter what their previous
positions).
Actuation of 3 will extend both A and B (no matter what their previous
positions).
Actuation of 4 will retract both A and B (no matter what their previous
positions).

Solution: Conveyor Selection
The cylinders A and B are mounted back to back, with the piston rod of cylinder A
fixed, all movement must therefore be in one direction only. The cylinder movements
are dictated by the operation of the four (4) push buttons, which can be operated in
any order. If the cylinders are of different stroke lengths, then four (4) different
positions can be obtained.
When the push button marked 1 is operated it passes air through to line 1, this in
turn allows signals to travel to valve 1.7 (port 12) and valve 2.7 (port 12), cylinder A
is thereby extended and cylinder B retracted.
When the push button marked 2 is operated is passes air through to line 2, this in
turn allows signals to travel to valve 1.7 (port 14) and valve 2.7 (port 14), cylinder A
is thereby retracted and cylinder B extended.
turn allows signals to travel to valve 1.7 (port 12) and valve 2.7 (port 14), cylinders A
and B are both extended.
turn allows signals to travel to valve 1.7 (port 14) and valve 2.7 (port 12), cylinders A
and B are both retracted.

Questions: Conveyor Selection
1. Why are the shuttle valves 1,5, 1,6, 2,5 and 2,6 used ?
....
...
2. What is it about the cylinders that creates the possibility of selecting 4

positions ?

3. If 3 positions were required what changes to the cylinders would be

required ?
4. If 4 cylinders were mounted back to back and nose to nose (rod to rod)
how many different positions could be selected ?

Answers: Conveyor Selection
1. Why are the shuttle valves 1,5, 1,6, 2,5 and 2,6 used ?
The shuttle valves are used because the switching signals for the
directional control valves 1,7 and 2,7 can come in each case from
either of two points (from either of two push buttons).
2. What is it about the cylinders that creates the possibility of selecting 4

positions ?
4 Positions can be selected due to the fact that the two cylinders are
mounted back to back and one piston rod is mounted so that it
cannot move. The actual number of positions is dictated by the
number of cylinders and whether they are of the same or different
stroke lengths. Two cylinders of different stroke lengths will give 4
positions (2 positions for each cylinder).
3. If 3 positions were required what changes to the cylinders would be

required ?
The cylinders would both need to be of the same stroke length.
4. If 4 cylinders were mounted back to back and nose to nose (rod to rod)
how many different positions could be selected ?
Presuming that each cylinder is of a different stroke length then the

number of positions available for selection would be 16.
The number of positions is determined by each cylinder having 2

positions and the total number of cylinders becoming the power
therefore in this case the result is 2 to the power of 4 (24).

Exercise: Lift and Transfer Station
Packages arrive at a transfer station, upon actuating a package register, they are
lifted by cylinder A (lift cylinder), to a second level, when this level is reached, the
package is pushed onto the roller track by cylinder B (transfer cylinder). Once
cylinder B has fully extended, cylinder A will retract (lower), only after cylinder A
has reached its initial (fully retracted) position, will cylinder B retract.
A Motion STEP Diagram is shown, illustrating the sequence of movements.
Cylinder A remains retracted until the next package arrives, when it does the cycle
will be repeated.

Solution: Lift and Transfer Station
In the at rest condition of the circuit both cylinders 1.0 (A) and 2.0 (B) are fully
retracted and the roller valves 1.2 and 2.2 are actuated. When the start valve
(package register 1.1) is actuated the air will pass, via valve 1.2 to valve 1.4 (port
14), this valve (1.4) is switched and cylinder 1.0 (A) extends. When the cylinder is
fully extended roller valve 2.1will be actuated, this sends a signal to port 14 of valve
2.3, which switches and extends cylinder 2.0 (B), at the fully extended position of
cylinder 2.0 (B) valve 1.3 is actuated, this sends a signal to the valve 1.4 (port 12),
which can switch, due to the signal on the opposite side has been removed when
cylinder 2.0 (B) extended. Once the valve 1.4 is switched cylinder 1.0 (A) retracts.
When the cylinder is fully retracted roller valve 2.2 is actuated this generates a signal
to switch valve 1.4 (port 12) to the position as drawn, this retracts cylinder 2.0 (B).
When cylinder 2.0 (B) is fully retracted roller valve 1.2 is actuated and the circuit is
back to its start condition.

Questions: Lift and Transfer Station
1. What term is given to a sequence when the cylinders move in the same
order e.g. A+ B+ A- B- or A+ B+ C- A- B- C+ ?
2. If the package register was to stick in the operated condition what would
happen and why ?
.
3. What is the purpose of valve 1,2 in this circuit ?
4. The lift cylinder (A / 1,0) is only required to do a job of work in the extend
(lift) mode why therefore is a single acting cylinder not used in this
application ?

Answers: Lift and Transfer Station
1. What term is given to a sequence when the cylinders move in the same
order e.g. A+ B+ A- B- or A+ B+ C- A- B- C+ ?
These sequences are called repeat pattern sequences, the cylinders

repeat the same sequence of movements on each cycle if the
sequence of cylinder movements followed a differing pattern this is
known as a non-repeat pattern sequence.
2. If the package register was to stick in the operated condition what would
happen and why ?
The system would keep cycling once the air was turned on and the
only way to stop it would be to turn the air off (or get the package
register to switch off). This is due to the fact that a permanent supply
is present at the valve 1,2 so that each time this valve is actuated the
cycle starts again.
The valve 1,2 provides an interlock to ensure that the cycle of

operations must be completed before it is possible to start the next
cycle.
4. The lift cylinder (A / 1,0) is only required to do a job of work in the extend
(lift) mode why therefore is a single acting cylinder not used in this
application ?
Standard single acting cylinders would not be available in a long

enough stroke length.

Exercise: Embossing Machine
Plastic components are to be embossed with a serial number, they are manually
placed into a holder. This holder is then fed by means of a double acting cylinder
(A), to a position below the embossing cylinder (B), once this location is reached
the embossing cylinder (B) will extend and emboss the component. Once the
component is embossed, cylinder B must fully retract first, then cylinder A may
retract to its initial position. At this point the cycle stops, the component is removed
from the holder and a new component is loaded. Each cycle is started by means of a
push button.
A Motion STEP Diagram is shown, illustrating the sequence of movements.

Solution: Embossing Machine
Circuit with idle return roller valves.
retracted and the roller valve 1.2 is actuated. When the start push button (1.1) is
operated the air will pass to valve 1.4 (port 14), this valve (1.4) is switched and
cylinder 1.0 (A) extends, the idle return roller valve 2.1 will be actuated, (slightly
before the end of the cylinder stroke), this sends a signal to port 14 of valve 2.3,
which switches and extends cylinder 2.0 (B), (by the time cylinder 1.0 (A) has
reached its fully extended position it has travelled over valve 2.1 and released it
again, which removes the signal from valve 2.3). At the fully extended position of
cylinder 2.0 (B) the valve 2.2 is actuated, this sends a signal to the valve 2.3 (port
12), which can switch, due to the signal on the opposite side has been removed
when the idle return roller valve was released. Once the valve 2.3 is switched
cylinder 2.0 (B) retracts. As the cylinder retracts it actuates idle return roller valve 1.3
(again slightly before the end of the cylinder stroke) this generates a signal to switch
valve 1.4 (port 12) to the position as drawn, this retracts cylinder 1.0 (A). When
cylinder 2.0 (B) is fully retracted the actuation of valve 1.3 is removed (due to it being
of the idle return roller type) and the signal is therefore removed from port 12 of valve
1.4. The circuit is now back to its start condition.
The idle return roller valves (1.3 and 2.1) are used to eliminate the possibility of
conflicting signals, however, nowadays this is not a preferred method of circuit
design, as there are too many potential problems when using this type of valve.

Questions: Embossing Machine
(Circuit with idle return roller valves)
1. What is the name given to the valves 1,3 and 2,1 ?
....
...
2. Why are valves 1,3 and 2,1 used ?
.
3. What do the arrows at position 2,1 (in relation to cylinder 1,0) and 1,3 (in
relation to cylinder 2,0) signify ?
4. Give two disadvantages associated with the use of this type of valve:
1) ..
2) ..

Answers: Embossing Machine
(Circuit with idle return roller valves)
1. What is the name given to the valves 1,3 and 2,1 ?
3/2 way Idle return roller valve, normally closed type sometimes
called a one-way trip valve.
2. Why are valves 1,3 and 2,1 used ?
If normal roller valves were used in this circuit there would be

trapped signals created at port 12 of valve 1,4 (in the case of valve
1,3) and port 14 of valve 2,3 (in the case of valve 2,1) the use of idle
return roller valves eliminates this problem.
3. What do the arrows at position 2,1 (in relation to cylinder 1,0) and 1,3 (in
relation to cylinder 2,0) signify ?
These arrows show the direction of cylinder travel when the idle
return roller valve is actuated (the live direction) when the cylinder
travels in the opposite direction the idle return roller becomes
inoperative.
4. Give two disadvantages associated with the use of this type of valve:
1) The mounting position of the valve is very critical (more so than

with standard roller valves).
2) The roller is reset by means of a weak spring which always has the
potential of failing.
3) The speed of cylinder travel sometimes has to have slowed down

so that the idle return roller valve is actuated long enough for its
output signal to achieve its task with fast operating systems this
often means this type of valve cannot be used.
4) As the cylinder passes over the roller of the valve and then
releases it again at the end of its stroke this type of valve can be
difficult to fault find (due to cannot tell whether the valve has been
actuated or not).

Latching circuit version
retracted and the roller valve 1.2 is actuated, which keeps a signal on port 12 of valve
1.4, via the latching valve (1.3). When the start push button (1.1) is operated the air
will pass to valve 1.4 (port 14) and valve 1.3 (port 14). The valve 1.3 is switched first
(there is no signal on its opposite side), this then takes the signal away from port 12
of valve 1.4, which itself will then switch. When 1.4 switches cylinder 1.0 (A) extends.
Once this cylinder has fully extended the roller valve 2.1 will be actuated, this sends
a signal to port 14 of valve 2.3 (via the valve 1.3) this switches valve 2.3 which in turn
generates the extension of cylinder 2.0 (B). At the fully extended position of cylinder
2.0 (B) the valve 2.2 is actuated, this sends signals to both the valve 1.3 (port 12)
and valve 2.3 (port 12), once the valve 1.3 is switched the signal at port 14 of valve
2.3 is lost and this valve (2.3) will then switch back to the condition as drawn, which
then puts air to the front of cylinder 2.0 (B), which retracts. Upon reaching its fully
retracted position cylinder 2.0 (B) will actuate valve 1.2 this sends a signal, via valve
1.3 to port 12 of valve 1.4, which then switches, air is then placed in the front
chamber of cylinder 1.0 (A), which will then retract. When cylinder 1.0 (A) is fully
retracted the circuit is back to its start condition.

(Latching circuit version)
1. Give an advantage of this solution over the roller version:
....
...
.
3. How does valve 1,2 differ from valves 2,1 and 2,2 ?
4. What would happen in the event of the push button valve sticking in the
operated condition ?

(Latching circuit version)
1. Give an advantage of this solution over the roller version:
This solution uses standard roller valves and therefore suffers from
none of the potential problems associated with that type of valve.
Valve 1,3 is used to switch an air supply between two sections of the
circuit and thereby avoid trapped signals any signals that are likely
to result in a trapped signal situation are split by means of valve 1,3
so that they cannot both be live at the same time.
3. How does valve 1,2 differ from valves 2,1 and 2,2 ?
The valve 1,2 itself does not differ from valves 2,1 and 2,2 but it is
drawn in its actuated condition shown by the fact that the

connections are all made to the left hand square and the symbol
against the roller of the valve signifies the mechanical operation on
the valve.
4. What would happen in the event of the push button valve sticking in the
operated condition ?
If the push button was to stick a permanent signal is applied to the

control valve 1,4 (port 14) and the latching vale 1,3 (port 14) this
would mean that cylinder A (1,0) extends and remains extended at the
end of its stroke it actuates valve 2,1 which would send a signal to
valve 2,3 (port 14) switching this valve and extending cylinder B (2,0)
at the end of its stroke valve 2,2 is actuated this then causes trapped
signals at valves 1,3 and 2,3 the sequence will therefore stop at this
point.

Cascade circuit version
In the at rest condition of the circuit both cylinders A and B are fully retracted and
subsequently the roller valves a0 and b0 are actuated. The Group Selector Valve
(GSV) is in the condition shown, with the supply (port 1) connected through to the
output 4, thus making group 2 live, the supply for the start push button valve is taken
from group 2. When this push button is operated the air will pass through it and
valve a0, this will then switch the GSV and mains air is now transferred from group 2
into group 1, the first operation that takes place in this group is for cylinder A to
extend. At the fully extended position of cylinder A the valve a1 is actuated, as this
valve is supplied from group 1 it is live and can therefore pass a signal to switch the
valve controlling cylinder B this valve changes condition and the cylinder then
extends. Once cylinder B reaches its fully extended position the valve b1 is
actuated, this valve is supplied from group 1 and the output from it is then used to
switch the GSV and make group 2 live, at this stage group 1 is opened to exhaust,
(with the cascade system it is not possible to have more than 1 group live at any one
time, thereby avoiding conflicting signals). When group 2 becomes live the first thing
to happen is that cylinder B will be retracted, at the completion of this movement
valve b0 is actuated, this valve is supplied from group 2, it is live and a signal is
passed to switch the valve controlling cylinder A. When this valve is switched,
cylinder A retracts, at the fully retracted position, valve a0 is actuated, and the
system is back to its start condition.

(Cascade circuit version)
1. What do the following refer to in relation to a cascade circuit ?
a0 ..
a1 ..
b0 ......
b1 ..
2. What name is given to the 5/2 way valve drawn below the cascade group
lines (1 and 2) ?
.
3. Break the following sequence into groups for a cascade circuit ?
A+ B+ B- C+ C- B+ B- A-
4. Where else in the circuit could the start push button be placed and still
maintain the same result ?

(Cascade circuit version)
1. What do the following refer to in relation to a cascade circuit ?
a0 Limit switch (roller valve) situated at the instroke position of

cylinder A.
a1 Limit switch (roller valve) situated at the outstroke position of

cylinder A.
b0 Limit switch (roller valve) situated at the outstroke position of

cylinder B.
b1 Limit switch (roller valve) situated at the instroke position of

cylinder B.
2. What name is given to the 5/2 way valve drawn below the cascade group
lines (1 and 2) ?
Group selector valve.
3. Break the following sequence into groups for a cascade circuit ?
I II III IV
A+ B+ B- C+ C- B+ B- A-
4. Where else in the circuit could the start push button be placed and still
maintain the same result ?
The start push button may be installed in the line coming from
cascade group line 1 and feeding the signal port 14 of the control
valve for cylinder A. The result would be the same although the
group selector valve would be switched at the end of the cycle
whereas with the present system the group selector valve is not
switched until the start push button is operated.

Stepper circuit version (4-group)
subsequently the roller valves a0 and b0 are actuated. When the start push button is
operated, the air will pass through it and valve a0, this will then switch on the first
group of the stepper, this gives an output signal for cylinder A to extend. Once the
cylinder A has fully extended the roller valve a1 will be actuated, this sends a signal
to the stepper unit, which then switches into the second group and an output signal is
then generated for the extension of cylinder B. At the fully extended position of
cylinder B the valve b1 is actuated, this sends a signal to the stepper unit, which
then switches to its third group, giving an output signal to retract cylinder B. Upon
reaching its fully retracted position cylinder B will actuate valve b0, this switches the
stepper to its fourth and final group, an output signal is then generated that will
retract cylinder A. When cylinder A is fully retracted, the valve a0 is actuated and
the circuit is back to its start condition.
With the stepper system it is only possible for one group to be live at any one time
and therefore only one output signal can be present at any one time, for this reason
conflicting signals do not become a problem (for example the second and third
groups of this circuit).

Stepper circuit version (2-group)
subsequently the roller valves a0 and b0 are actuated. When the start push button is
operated, the air will pass through it and valve a0, this will then switch on the first
group of the stepper, this gives an output signal for cylinder A to extend. Once the
cylinder A has fully extended the roller valve a1 will be actuated, this sends a signal
to extend cylinder B. At the fully extended position of cylinder B the valve b1 is
actuated, this sends a signal to the stepper unit, which then switches to its second
group, giving an output signal to retract cylinder B. Upon reaching its fully retracted
position cylinder B will actuate valve b0, this switches, an output signal is then
generated that will retract cylinder A. When cylinder A is fully retracted, the valve
a0 is actuated and the circuit is back to its start condition.
With the stepper system it is only possible for one group to be live at any one time
and therefore only one output signal can be present at any one time, for this reason
conflicting signals do not become a problem.

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Pneumatics

2001 MECHATRONICS International Ltd, Lichfield

Part No. MEX001

MECHATRONICS International Ltd

MECHATRONICS International Ltd

Suggestions and recommendations for improvements would be welcomed by the

MECHATRONICS International Ltd

2 Date Stamping of Product

4 Panel Removal from a Jig

6 Foundry Ladle Control

8 Component Test Machine

9 Coldroom Door Control

10 Roof Ventilator Control

14 Hopper Door Control

16 Blister Pack Assembly

18 Lift and Transfer Station

MECHATRONICS International Ltd

Design a circuit to meet these requirements.

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MECHATRONICS International Ltd

2. List two disadvantages of a single acting spring return cylinder:

4. Convert the following pressures as required:

b) 72.5 PSI = Bar

MECHATRONICS International Ltd

2. List two disadvantages of a single acting spring return cylinder:

Can only be used to do work in one direction of travel (that controlled

Increased overall length due to the space required for the

maximum bore available is 100mm and maximum stroke is also

4. Convert the following pressures as required:

b) 72.5 PSI = 5 Bar

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Design a circuit to meet these requirements.

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MECHATRONICS International Ltd

4. Does a double acting cylinder deliver a greater force on the extend or

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3) Lever with detent

6) Solenoid (indirect, with air pilot)

4. Does a double acting cylinder deliver a greater force on the extend or

On the extend stroke due to force being developed by means of

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The cylinder bore is to be 150mm and its stroke is to be 100mm.

Design a circuit to meet these requirements.

MECHATRONICS International Ltd

MECHATRONICS International Ltd

MECHATRONICS International Ltd

The number identifies a pilot port, when a signal is applied to this

The direction which air is allowed to flow through the valve.

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Design a circuit to meet these requirements.

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2. Show using a truth table its function :

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2. Show using a truth table its function :

There will be an output at 2 in this condition (both signals present)

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Products (e.g. parcels) are to be separated in a distribution warehouse, where the

Design a circuit to meet these requirements.

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MECHATRONICS International Ltd

2. With the valve shown what is the effect of:

a) Placing a signal (pressure) on port 14