ERT 457

DESIGN OF AUTOMATION
SYSTEMS

Powerpoint Templates

Munira Mohamed Nazari

PPK Bioproses
UniMAP

Lecture 3:
Actuators and Drivers

Course Outcome

CO 2
Ability to design (C5) automation
system for agricultural and biological
production system.

Course Outline

Introduction
Pneumatic & Hydraulic Actuation Systems
Electrical Actuation Systems
Mechanical Actuation Systems

INTRODUCTION

Why we automated systems in

agricultural area?
To fulfill requirement of modern farming.
Reduce labor work and cost.
Reduce time.

Help you to improve your agricultural application

to be even more productive and comfortable to
use.

Actuators in agriculture
Actuator solutions in spreaders adjusting the
amount of fertilizers.
Sprayer, actuator control height and angle of
outlet nozzle.
In chopper, actuator used to adjust the outlet
direction.
Electric actuators used to improve ergonomics
and comfort in a number of applications such as
adjustment of steering wheels, seats and
ventilation.

Sensor vs Actuator
A sensor
monitors the variable such as pressure and temperature and send a
signal to a transmitter or indicator.

An actuator
Hardware devices that convert a controller command signal into a
change in a physical parameter.
The change is usually mechanical (eg: position or velocity).
An actuator is a transducer because it changes one type of physical
quantity into some alternative form.
An actuator is usually activated by a low-level command signal, so
an amplifier may be required to provide sufficient power to drive the
actuator.

Actuation Systems
Practically every industrial process requires objects to be moved, manipulated, held, or subjected to
some type of force.
The most commonly employed methods for producing the required forces/motions are:

Air Pneumatics
Liquids Hydraulics
Electrical motors, solenoids.
Mechanical

A Brief System Comparison

The task considered is how to lift a body by a distance x mm. such

tasks are common in manufacturing industries.

Electric Actuators - motor

Drives & Control Engineering for Actutors

Energy (Medium)

Control

Drive

Actuator Type

Electrical
- Electrical current

Contactor and relay

Power
control
contactor
Digital and analog control
-Wired program
-Freely programmable
system

DC motor
AC motor
Stepper motor
Solenoid

Pneumatics
- Compressed air
from compressor

Digital control
Conventional valve
technology
Solenoid
Pneumatic logic

Directional
valve
Flow control
valve

Motors
Cylinders
Tools-gripper

Hydraulics
- Hydraulic fluids
using pump

Mechanical driven
Manual driven
Solenoid

Directional
valve
Flow control
valve
Special valve

Motors
Cylinders

PNEUMATIC & HYDRAULIC

ACTUATION SYSTEMS

Actuate large valve & highpower control device

PNEUMATIC
SIGNALS

Compressibility of air

More high-power control

device - expensive
HYDRAULIC
SYSTEMS

Oil leaks causes hazard

Pneumatic Vs Hydraulic
Application
Hydraulics are used for power and precision.
Pneumatics are used for light weight and speedy applications.

Material used in the construction of the components.

Hydraulic components are mainly made from steel.
Pneumatic components are made from plastic and mom-ferrous
materials.

However, the materials used in the system may have to

withstand some of the following conditions:

Heat
Cold
Mechanical damage
Dust
Chemical attack

Pneumatic Vs Hydraulic
When either pneumatic or hydraulic systems are equally for
an application the following should be considered.
Hydraulics generally calls for a greater capital outlay.
Hydraulic power generally cheaper on an energy basis.
Installation of hydraulic equipment generally requires a power pack
for each machine.
Hydraulics with multiple machines generally requires a power pack
for each machine.
Pneumatic machinery can be plugged into a ring main.

Pneumatic Vs Hydraulic
Comparison Table
HYDRAULIC

PNEUMATIC

ENERGY SOURCE

Electric motor
Int. combustion engine

Electric motor
Int. combustion engine

ENERGY STORAGE

Accumulator

Air receiver

DISTRIBUTION SYSTEM

Very localized

Ring main

Not easy to expand

Easy to modify and

change

CAPITAL COST

High

Lower

ENERGY COST

Medium

Higher

ROTARY ACTUATOR

Low speed
Good control

High speed
Control - difficult

LINEAR ACTUATOR

High force

Medium force

FLEXIBILITY

Pneumatic Vs Hydraulic
Comparison Table (cont)
HYDRAULIC

PNEUMATIC

CONTROLLABLE FORCE

High degree of control

and precision with high
forces.

Control difficult with

high forces.

MAINTENANCE

Expansive
Fluid replacement/top
up

Cheaper
No fluid replacement

SAFETY

Oil may leak

Fire hazard
Chemical/environment
al

Explosive failure
Noisy

Hydraulics Definition
Is the science of
transmitting force
and/or motion through
the medium of a
confined liquid.
Power is transmitted
by pushing on a
confined liquid.

Hydraulic Systems
Hydraulic systems schematic diagram.

Prevent the oil

being back to
the pump

Smooth out
any short term
fluctuations
output oil
pressure

Release
pressure rise
about safe
level.

Hydraulic Systems
Hydraulic pumps.
Gear pump two close meshing gear rotated.
Vane pump spring loaded sliding vanes.
Piston pump
Radial piston pump - cylinder block is rotate.
Axial piston pump move axially.

Hydraulic Systems
Gear pump
Advantages
Widely used
Low cost
Robust

Weaknesses
Leakage
Limit efficiency

Gear wheels rotate in opposite direction.

Fluid forces through pump, become trapped between gear teeth.
Fluid transferred fro the inlet port to be discharged at the outlet port.

Hydraulic Systems
Vane pump
Spring loaded sliding vanes
slotted in a driven motor.
Rotor rotates vanes follow
contours of the casing.
Fluid trapped between
successive vanes and casing.
Transported round from inlet to
outlet.

Advantage
Leakage less than
gear pump.

Hydraulic Systems
Radial piston pump

Cylinder block rotates hollow

pistons with spring return, to move
in and out.
Fluid drawn from inlet port.
Fluid transported round for
ejection from the discharge port.

Axial piston pump

Piston move axially in a rotating

cylinder block move by contact
with the swash plate.
Shaft rotates move the pistons.
Air sucks (piston opposite the
inlet), air expelled (opposite the
discharge port.

Hydraulic Systems
Piston pump advantages.
High efficiency
Can be used at higher hydraulic pressures
than gear (below 15 MPa) or vane pumps.

Pneumatic Systems
Pneumatic systems schematic diagram
Drive a
compressor

To reduce
noise level

To reduce
temperature
Provide protection
against pressure
in the system.

Increase volume
of air

Remove
contamination
and water

Pneumatic Systems
Types of an air compressors.
Are ones in which successive volumes of air are isolated
and then compressed.

Single acting, single stage, vertical, reciprocating

compressor.
Rotary vane compressor.
Screw compressor.

Pneumatic Systems
Single acting, single stage, vertical, reciprocating
compressor

Piston
Spring loaded
inlet valve

The descending piston causes

air to be sucked into the chamber.
Piston rise again trapped air
forces the inlet valve to close
become compressed.
Air pressure risen sufficiently
spring loaded outlet valve open
trapped air flows into the
compressed air system.
After the piston has reached the
top dead centre it then begins to
descend and the cycle repeat
itself.

Pneumatic Systems
Rotary vane compressor.
Has a rotor mounted eccentrically
in a cylindrical chamber.
Rotation causing the vanes to be
driven outwards against the walls of
the cylinder.
Air is trapped in pockets formed
by the vanes rotor rotates
pockets become smaller and the air
is compressed.
Compressed packets of air thus
discharged from the discharge port.

Pneumatic Systems
Screw compressor.

Screw rotate air drawn into the

space between the screws.
Air trapped move along the
length of the screws and
compressed (space progressively
smaller), emerging from the
discharge port.

Valves
Are used with hydraulics and pneumatics systems
to direct and regulate the fluid flow.
Two types:
Finite position
To allow or block fluid flow and so can be used to switch
actuators on or off.
Can be used for directional control to switch the flow from one
path to another and so from one actuator to another.

Infinite position
Able to control flow anywhere between fully on and fully off,
Are used to control varying actuator forces or the rate of fluid
flow for a process control situation.

Directional Control Valves

To direct the flow of fluid through a system.
Not intended to vary the rate of fluid flow but are
either completely open or completely closed.
Example: on/off devices.
widely used to develop sequenced control systems.
Might be activated to switch the fluid flow direction by means of
mechanical, electric or fluid pressure signals.

Common types:
Spool valve
Poppet valve

Directional Control Valves

Spool valve.

Directional Control Valves

Poppet valve.

Directional Control Valves

Valve symbols
Consists of a square for each of its switching positions.
(eg: poppet valve two position valve two squares)

Flow path

Port labels:
1 or P = pressure supply
3 or T = hydraulic return
3 (R) or 5 (S) = pneumatic exhaust
2 (B) or 5 (A) = output
Initial connections ( 4ports)

Flow shut-off

Directional Control Valves

Valve actuation symbols.

Directional Control Valves

Symbol for two port, two position poppet valve.
Can be describe as a 2/2 valve.
Number of ports

Number of positions

Output port

Push button

Spring

Pressure
supply port

Directional Control Valves

Single-solenoid valve.

How many port and position??

Answer: 3/2

Directional Control Valves

Symbol for a 4/2 valve.
Output port

Output port

Solenoid

Spring

Pressure
supply port

Pneumatic
exhaust

Directional Control Valves

Lift system.
A simple example of an application of valves in a
pneumatic lift system.

Directional Control Valves

Pilot-operated Valve
To overcome a problem of too large force required to
move the ball or shuttle in a valve for manual or solenoid
operation. One valve (pilot valve) is used to control a
second valve (main valve).

Pilot pressure
line

Small capacity &

can be operated
manually or by a
solenoid.

Directional Control Valves

Directional Valves
Free flow can only occur in one direction through the valve.

The ball being pressed against the spring. Flow in other

direction is blocked by the spring forcing the ball against its
seat.

Pressure Control Valves

3 main types.
Pressure-regulating valves
To control the operating pressure in a circuit and maintain it at a
constant value.

Pressure-limiting valves
As safety device.
The valve opens and vents to the atmosphere, or back to the
sump if the pressure rises above the set safe value.

Pressure Control Valves

Pressure sequence valves.
used to sense the pressure of an external line and give a signal
when it reaches some preset value.

The valve switching on

when the inlet pressure
reaches a particular
value and allowing the
pressure to be applied to
the system that follow.

Cylinders
Pneumatic and hydraulic cylinder is an example
of linear actuator.
Same principles, differences in term of size as
hydraulic required high pressure.
Consists of a cylindrical tube along which a
piston/ram cam slide.
2 basic types:
single acting cylinder and
double acting cylinder.

Cylinders
Single acting cylinder.
Used when the control pressure is applied to just one side
of the piston, a spring often being used to provide the
opposition to the movement of the piston. The other side is
open to the atmosphere.

Cylinders
Control of a single-acting cylinder with (a) no current through solenoid, (b) a current
through the solenoid.

When a current passes through the solenoid, the valve switches position and
pressure is applied to move the piston along the cylinder.
When the current ceases, the valve reverts to its initial position and the air is vented
from the cylinder.

Cylinders
Double acting cylinder.
Used when the control pressure are applied to each side
of the piston. A differences in pressure between the 2
sides, results in motion of the piston. The piston being able
to move in either direction along the cylinder as a result of
high-pressure signals.

Cylinders
Control of a double-acting cylinder with solenoid, (a) not activated, (b)
activated.

Current through one solenoid causes the piston to move in one direction with
current through the other solenoid reversing the direction of motion.

Cylinders
The choice of cylinder, determined by force required
to move the load and speed required.
Hydraulic capable larger force
Pneumatic capable greater speed
FORCE

Force produced
by cylinder

Working
pressure

F = A
Cross-sectional
area of cylinder

HYDRAULIC
FLUID FLOW

Q = Av

Speed

Cant use for pneumatic !!

-since its speed depends
on the rate at which air
can be vented ahead of
the advancing piston.

Cylinders
Cylinder Sequencing
Used as a sequential control of extensions and retractions
of the cylinder.
Cylinder reference letter A, B, C, D,
State of cylinder + sign = extended, - sign = retracted.
So sequence of operation = A+, A-, B+, B-

Cylinders
Cylinder Sequencing
Valve 1 is pressed applied pressure to valve 2 activated limit
switch b- - valve 3 is switched to apply pressure to cylinder A for
extension.
Cylinder A extends releasing limit switch a- - cylinder A fully
extended limit switch a+ operates switches valve 5 pressure
applied to valve 6 apply pressure to cylinder B piston extend.
Cylinder B extends releasing limit switch b- - cylinder B fully
extended limit switch b+ operates switches valve 4 pressure
applied to valve 3 applies pressure to cylinder A piston retracting.
Cylinder A retract releasing limit switch a+ - cylinder A fully retracted
limit switch a- operates switches valve 7 pressure applied to
valve 5 applies pressure to cylinder B piston retracting.
Cylinder B retracts releasing limit switch b+ - cylinder B fully
retracted limit switch b- operates to complete the cycle.

Servo and Proportional Control Valve

Are both infinite position valves which give a valve spool
displacement proportional to the current supplied to a
solenoid.
Servo :

have a torque motor to move the spool within a valve.

High precision
Costly
Used in a closed-loop control system.

Servo and Proportional Control Valve

Proportional control valve:
Less expensive
Have the spool position directly controlled by the size of
current to the valve solenoid.
Used in open-loop control systems.

Process Control Valve

Used to control the rate of fluid flow.
Common form of pneumatic actuator used with
process control valves is the diaphragm actuator.
Consists of a diaphragm with the input pressure
signal from the controller on one side and
atmospheric pressure on the other. Differences in
pressure being termed the gauge pressure.
The diaphragm is made of rubber which is
sandwiched in its centre between two circular steel
discs.

Process Control Valve

Effect of changes in the input pressure.

Process Control Valve

If the shaft moves through a distance x, and
compression of spring is proportional to the force,

F = kx
and, displacement of the shaft is proportional to the
gauge pressure.

kx = PA
So, pressure P,

P=F/A

Diaphragm area

Process Control Valve

Control Valve Sizing
Procedure of determining correct size of valve body.
Flow rate
Flow rate

Q = Av (P / )

Valve flow coefficient

Density of the fluid

Pressure drop across the valve

Valve size (mm)

Flow coefficient
480

640

800

960

1260

1600

1920

2560

Cv

14

22

30

50

75

110

200

Av x 10-5

19

33

52

71

119

178

261

474

Table 7.1

Process Control Valve

Example:
Consider the problem of diaphragm actuator to be used to open a
control valve if a force of 500 N must be applied to the valve. What
diaphragm are is required for a control gauge pressure of 100 kPA.

A=F/P
= 500 / (100 x 10)
= 0.005 m

Process Control Valve

Example:
Consider the problem of determining the valve size for a valve that is
required to control the flow of water when the maximum flow required
is 0.012 m/s and the permissible pressure drop across the valve at
this flow rate is 300 kPa. Density of water is 1000 kg/m

Q = Av (P / )
Av = Q ( /P)
= 0.012 (1000 / 300 x 10)
= 69.3 x 10-5 m
So, the valve size is 960 mm.

Problem 7.9
A hydraulic cylinder is to be used to move a
workpiece in a manufacturing operation
through a distance of 50mm in 10 s. A force
of 10 kN is required to move the workpiece.
Determine the required working pressure and
hydraulic liquid flow rate if a cylinder with a
piston diameter of 100mm is available.
P = 1.27 Mpa & Q = 3.93 x 10-5 m/s

Problem 7.12
What is the process control valve size for a
valve that is required to control the flow of
water when the maximum flow required is
0.002 m/s and the permissible pressure drop
across the valve at this flow rate is 100 kPa?
The density of water is 1000 kg/m.
The process control valve size = 480 mm

THANK YOU..