DJJ5123 PNEUMATIC &

HYDRAULICS

3.0 PNEUMATICS CIRCUIT DESIGN

PNEUMATICS CIRCUIT

2
PNEUMATICS CIRCUIT

 A pneumatic circuit is an interconnected set of components that convert

compressed gas (usually air) into mechanical work. In the normal sense of the
term, the circuit must include a compressor or compressor-fed tank.

 Pneumatic circuit diagram for one cylinder can be categorised to:

a. Direct method
b. Indirect method

3
a. Pneumatic-Direct method

 The cylinder is actuated directly via a

manually or mechanically actuated valve,
without any intermediate switching of
additional directional control valves.

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Example: Direct control of single acting cylinder

5
Example: Direct control of double acting cylinder

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b. Pneumatic-Indirect method

 Need support from directed control valve before actuator is moving.

 Cylinderswith large piston diameters have high air consumption rates.

Control elements with high nominal flow rates must be used to actuate
them. In this case, the indirect control is recommended. Thus, the
signal which is generated by the smaller valve will provide the force
required in order to switch the main control element. To achieve the
indirect control, a single and/or double pilot valves will be required.

7
Example: Indirect control of single acting cylinder

8
Example: Indirect control of double acting cylinder

9
Example: Indirect control of double acting cylinder

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 R Y CUIT Direct Indirect
MA IR
UM SC
S TIC
A
E UM
PN

Single Acting
Cylinder

Double Acting
Cylinder

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ELECTRO PNEUMATICS CIRCUIT

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ELECTRO PNEUMATICS CIRCUIT
 The most used pneumatic actuation systems are electrically controlled
systems. These systems are called electro-pneumatic actuation systems.
 Electro-pneumatic control system is a combination of electrical unit and
pneumatic control unit both in one unit. A number of electro-pneumatic
elements are used in electro-pneumatic controls. In electro-pneumatic
circuits solenoid operated directional control valves, limit switches and
pressure switches are used.
 Electro pneumatic circuit diagram for one cylinder can be categorised to:
a. Direct method
b. Indirect method

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Advantages of Electro-Pneumatic Systems:-
 The system allows easy automation of complex industrial processes.
 The high speed of signal transmitting and processing leads to the significant
enhancement of the productivity of the automation system.
 Electric equipment costs less than pneumatic equipment.
 Significant loads are controlled with a reduced control signal.
 The loading gauge of the control equipment is reduced.
 Electronic programmers and process computers are used for the control of the
system

Disadvantages of Electro-Pneumatic Systems:-

 The systems use two supply units (pneumatic and electric).

 Functioning is not allowed in flammable environments, in environments
subjected to hazard of explosion or in high humidity conditions.
 Hazard of electrocution is present.
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a. Electro Pneumatic-Direct method
 Direct control is the control of an electro-pneumatic valve without
using intermediate components such as a relay, a contactor or an
industrial computer (PLC). The valve is connected directly to electric
switch as shown below:
Advantages of direct control
 Simple and easy.
 Less wiring
 Cheap.

Disadvantages of direct control

 Remote control is not possible.
 Switching more than one valve at a time is not possible.
 Latching is not possible.
 Design improvement is not flexible.

the solenoid valve is connected 15

directly to the switch
Example: Direct Control of single acting cylinder

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Example: Direct control of a double acting cylinder by using 5/2 directional
control valve, single solenoid

pneumatic circuit electric circuit

Background:
A direct control circuit is used to control a 5/2 DCV single solenoid by
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using a push button switch. Activating the pushbutton will energize the
coil (solenoid) which in turn will actuate (operate) the valve.
b. Electro Pneumatic-Indirect method
 Indirect control is the control of an electro-pneumatic valve using
intermediate components such as relays, contactors or programmable
logic controllers (PLC).

Advantages of indirect control systems

 Remote control is possible
 Switching more than one valve at a time is possible
 Latching is possible.
 Flexible design improvement and development.
 Incorporating logic operating conditions (OR, AND conditions)

Disadvantages of direct control

 Complicated
 More wiring
 More cost involved

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Example: Indirect Control of single acting cylinder

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Example: Indirect control of a double acting cylinder

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 Y TICS
M AR MA Direct Indirect
U M NEU
S P IT
O
R RCU
T
L OC CI
E

Single Acting
Cylinder

Double Acting
Cylinder

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PNEUMATICS CIRCUIT -
SEQUENCE CONTROL

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PNEUMATICS CIRCUIT - SEQUENCE
CONTROL

 Pneumatic circuit for sequence control can be categorised to:

a. Basic method
b. Step Counter method
c. Cascade method

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a. Basic Circuit 1.Silinder 2 tindakan
2.Bina susunan pergerakan
Example: A+ B+ A- B-

K3
K2 K4

a1 b1 a0

A+ B+ A- B-
K1

ST b0
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 3.Bina silinder & dcv
A+ B+ A- B-

a0 a1 b0 b1

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 4.Tempatkan limit
switch & ST mengikut
A+ B+ A- B- kumpulan

a0 a1 b0 b1

ST

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 A+ B+ A- B-
5.Sambungkan komponen
mengikut kumpulan

a0 a1 b0 b1

ST

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Time Motion Diagrams A+ B+ A- B-

b1

b0
a1

ST a0
,
A+ B+ A- B-
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Time Motion Diagrams

b1

b0
a1

ST a0
,
A+ B+ A- B-
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Time Motion Diagrams

b1

b0
a1

ST a0
,
A+ B+ A- B-
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Time Motion Diagrams

b1

b0
a1

ST a0
,
A+ B+ A- B-
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b. Step Counter Circuit Design

 The step counter method of circuit design is a procedure

that eliminates the possibility of opposing signals.
 Opposing signals occurs when a directional control valve is
required to move but a pressure on the other side opposes
the motion.
 For example, if A- is pressurized and has not been
released, a signal to pressurize A+ will have no effect as
the DCV cannot move.

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Step-counter module
1. Preparation signal from previous
module

2. Feedback signal from previous

step-Input Signal

3. Switching signal to DCV-Output

Signal

4. Reset signal to previous module

5. Preparation signal to next module

6. Reset signal from next module

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The links between the step counter modules of each step are:

• Line 5 from the previous module joins to Line 1 of the current

module.

• Line 4 from the current module joins to Line 6 of the previous

module.

• Line 3 goes to activate the DCVs [A+, A-, etc.] that are found
on the Sequence Circuit.

• Line 2 joins the input signal that are found on the Sequence
Circuit for the particular step.

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METHOD:
I II III IV

A+ B+ B- A-

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Example 1:

Draw a pneumatic STEP COUNTER circuit base on sequence

A+ B+ B- A-

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Example 1: A+ B+ B- A- 1.Silinder 2 tindakan
2.Bina susunan pergerakan

I II III IV
a1 b1 b0

A+ B+ B- A-

S a0
T

37
 Example 1: A+ B+ B- A-
K2 K3 K4 3.Bina kumpulan (ikut
modul)
I II III IV
a1 b1 b0

A+ B+ B- A-
K1

S a0
T

38
 4.Bina silinder, dcv & modul

*Pastikan “(normally open) / activated room = left” pd modul terakhir

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5.Tempatkan limit switch & ST
mengikut kumpulan

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6.Sambungkan komponen
mengikut kumpulan

*Sambungan keluar u
port 3 bg setiap
modul adalah
mengikut sequence

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Time Motion Diagrams
A+ B+ B- A-
b1

b0
a1

ST a0
,

42
Time Motion Diagrams
A+ B+ B- A-
b1

b0
a1

ST a0
,

43
Time Motion Diagrams
A+ B+ B- A-
b1

b0
a1

ST a0
,

44
Time Motion Diagrams
A+ B+ B- A-
b1

b0
a1

ST a0
,

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Example 2:

Draw a pneumatic STEP COUNTER circuit base on sequence

A+ B+ B-
A-

46
Example 2: A+ B+ B-
A-

I II III
a1 a0
b1
A+ B+ B-
A-
S b0
T

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Solution:

48
 A+ B+ B-
A-

I II III
a1 a0
b1
A+ B+ B-
A-
S b0
T
Where to put these start
button and limit switch?

49
50
 A+ B+ B-
A-
Where to put
this
limit switch?
I II III
a1 a0
b1
A+ B+ B-
A-
S b0
T

51
52
 A+ B+ B-
A-
Where to put theses
limit switches?

I II III
a1 a0
b1
A+ B+ B-
A-
S b0
T

53
54
 A+ B+ B-
A-
How to draw all lines?
I II III
a1 a0
b1
A+ B+ B-
A-
S b0
T

55
56
 THE OPERATION OF
STEP COUNTER SEQUENCE

57
 a1 b0 b1
a0

CLICK
HERE

58
 a1 b0 b1
a0

59
 a1 b0 b1
a0

60
 a1 b0 b1
a0

61
 a1 b0 b1
a0

62
 a1 b0 b1
a0

63
 a1 b0 b1
a0

64
 a1 b0 b1
a0

65
 a1 b0 b1
a0

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c. Cascade Circuit Design

 Implementation of a sequence of actions by a full pneumatic

circuit is widely used in industries.
 Many industries like automotive, food, chemical and so on need
to use a full pneumatic system due to the hazardous area in the
site and limitation of use of the electricity in the system.

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METHODS
1. Code the cylinders with letters. Use positive and
negative signs to show the cylinders’ positions:
 positive sign to indicate the cylinder is completely
extended, and
 negative sign to indicate the cylinder is
completely retracted:
A+ B+ B- A-

2. Split the motion sequence into groups in a way that

any letter regardless of its sign appears only once in
each group:
A+ B+ | B- A-
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3. Number the groups:
A+ B+ | B- A-
I II
4. For each cylinder, consider two limit valves to signal
for the start and end of its motion and two 4/2 or 5/2
direction control valve to operate the cylinder.

I
II
1

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 L1
L2

CLICK HERE

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 L1
L2

CLICK HERE

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 L1
L2

72
 Example 2
A+ B+ | B- C+ A- | C-
I II III

I
II
III
1

2
CLICK HERE

73
 I
II
III
1
CLICK HERE

74
 I
II
III
1

2
CLICK HERE

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 I
II
III
1

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Example 3
A+ B+ | B- | C+ | A- C-
I II III IV

I
II
III
IV
1

77
Example:

Draw a pneumatic CASCADE circuit base on sequence

A+ B+ B- A-

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 1.Pembahagian kumpulan
utama

A+ B+ | B- A-

I II

79
 2.Silinder 2 tindakan
Sequence Circuit 3.Bina susunan pergerakan yg
mengandungi kumpulan,
A+ B+ B- A- kumpulan utama & im

Im
a1 b0

A+ B+ B- A-

b1

S a0
T

I II
80
 4.Bina silinder, dvc & im

a0 a1 b0 b1

L1
L2

81
Sequence Circuit
A+ B+ B- A-
Im
a1 b0

A+ B+ B- A-

b1

S a0
T
I II

Where to put these start

button and limit switch?

82
 a0 a1 b0 b1

L1
L2

ST

83
 Sequence Circuit
Where to put this A+ B+ B- A-
limit switch?
Im
a1 b0

A+ B+ B- A-

b1

S a0
T
I II

84
 a0 a1 b0 b1

L1
L2

ST

85
Sequence Circuit
A+ B+ B- A-
Im
a1 b0

A+ B+ B- A-

b1
Where to put this
limit switch? S a0
T
I II

86
 a0 a1 b0 b1

L1
L2

ST

87
Sequence Circuit Where to put this
limit switch?
A+ B+ B- A-
Im
a1 b0

A+ B+ B- A-

b1

S a0
T
I II

88
 a0 a1 b0 b1

L1
L2

ST

89
Sequence Circuit
A+ B+ B- A-
Im
a1 b0

A+ B+ B- A-

b1

S a0
T
I II How to draw
these lines?

90
 a0 a1 b0 b1

L1
L2

ST

91
Sequence Circuit
A+ B+ B- A-
Im
a1 b0

A+ B+ B- A-

b1

S a0
How to draw
T
this line? I II

92
 a0 a1 b0 b1

L1
L2

ST

93
Sequence Circuit
A+ B+ B- A-
Im
How to draw a1 b0
these lines?

A+ B+ B- A-

b1

S a0
T
I II

94
 a0 a1 b0 b1

L1
L2

ST

95
Sequence Circuit
A+ B+ B- A-
Im
a1 b0

A+ B+ B- A-

b1
How to draw
this line? S a0
T
I II

96
 a0 a1 b0 b1

L1
L2

ST

97
Sequence Circuit
A+ B+ B- A-
Im
a1 b0

A+ B+ B- A-
How to draw
this line?

b1

S a0
T
I II

98
 a0 a1 b0 b1

L1
L2

ST

99
Sequence Circuit
A+ B+ B- A- How to draw
these lines?
Im
a1 b0

A+ B+ B- A-

b1

S a0
T
I II

100
 a0 a1 b0 b1

L1
L2

ST

101
Time Motion Diagrams
A+ B+ B- A-
b1

b0
a1

ST a0
,

102
Time Motion Diagrams
A+ B+ B- A-
b1

b0
a1

ST a0
,

103
Time Motion Diagrams
A+ B+ B- A-
b1

b0
a1

ST a0
,

104
Time Motion Diagrams
A+ B+ B- A-
b1

b0
a1

ST a0
,

105
THE OPERATION OF
CASCADE SEQUENCE

106
 a0 a1 b0 b1

L1
L2

ST

107
 a0 a1 b0 b1

L1
L2

ST

108
 a0 a1 b0 b1

L1
L2

ST

109
 a0 a1 b0 b1

L1
L2

ST

110
 a0 a1 b0 b1

L1
L2

ST

111
 a0 a1 b0 b1

L1
L2

ST

112
 a0 a1 b0 b1

L1
L2

ST

113
 a0 a1 b0 b1

L1
L2

ST

114
 a0 a1 b0 b1

L1
L2

ST

115
 a0 a1 b0 b1

L1
L2

ST

116
 a0 a1 b0 b1

L1
L2

ST

117
 a0 a1 b0 b1

L1
L2

ST

118
 a0 a1 b0 b1

L1
L2

ST

119
 a0 a1 b0 b1

L1
L2

ST

120