Asian Journal of Multidisciplinary Studies

Vol. 2, No. 2, (2019)

ISSN 2651-6691 (Print)
ISSN 2651-6705 (Online)

Development of a Basic Electro-pneumatic Control Trainer

Jeff G. Pereyras
Pangasinan State University - Lingayen Campus
Lingayen, Pangasinan, Philippines
[email protected]

Abstract – A basic electro-pneumatic control trainer provides the students’ learning experience and
appreciation of the subject and course and for the professors’ demonstrations and evaluation of students’
performance during laboratory time. This study utilized a developmental type of research. The trainer board
was a 24 inches by 24 inches by ¾ inch marine plywood. It was cost-effective, space-efficient and portable.
It contained circuit breaker, plurality of din rails, plurality of terminal blocks, plurality of relays and relay
holders, plurality of normality open and closed push buttons, plurality of utility box, plurality of base plates,
plurality of 24VDC (Volt-Direct Current) 3/2 way solenoid valves, plurality of 24VDC indicator lights,
tubes duct, plurality of double-acting cylinders, plurality of clamps, and plurality of 24VDC proximity
sensors. All the devices were totally exposed for easy installation and familiarization. The plurality of input
and output devices terminals were pre-wired into the terminal blocks for faster installation and cost-
effective for trainers’ maintenance purposes. It was equipped with a low current circuit breaker to facilitate
safe operations and eliminate damages to all the devices considering the hard to find and the high cost of
the electro-pneumatic control components. It was cable of handling an industrial-like electro-pneumatic
control wiring installation, troubleshooting, and commissioning. The basic electro-pneumatic control
trainer utilized 24VDC as a power supply for the electrical circuit and a 60psi (pounds per square inch)
compressed air for pneumatic control as air supply and supported with the instructional module in basic
electro-pneumatics. Demonstration, interview and consultation with the faculty members of the College of
Technology, Pangasinan State University – Lingayen Campus teaching BIT major in Electrical, Electronics
and Mechanical Technology, the said utility model can perform all the activities listed in the instructional
module in basic electro-pneumatics which were also parallel to the real world industry of automation. A
basic electro-pneumatic control trainer was granted an Industrial Design (ID) patent by the Intellectual
Property Office of the Philippines while still waiting for subsequent formality examination report as a
pending application for a Utility Model (UM) patent by the same office.

Keywords: Electro-pneumatic control, Trainer, Pangasinan State University, Industrial design,

Utility model, Intellectual Property Office.

INTRODUCTION contactors combination. Third, signal outputs–

In many fields of industrial automation, these are the outputs that are acquired after
electro-pneumatics were now widely used. processing for solenoid activation and indicator
Electro-pneumatics were also extensively used in lights. Electro-pneumatic control comprises of
manufacturing, assembly and packaging systems. running pneumatic power systems for electrical
Relays have been integrated into electro- control. Solenoid valves were used as an
pneumatic control systems to satisfy the electrical and pneumatic system interface.
increasing call for more flexible automation. Devices such as sensors were utilized as feedback
There are three (3) significant steps are engaged components. Electro-pneumatic control
in electro-pneumatic control; First, signal input incorporates pneumatic and electrical systems
devices–these are generating signals such as and was used more commonly in industrial and
switches and contactors, as well as different kinds manufacturing businesses in particular for big
of touch proximity sensors. Second, signal applications [1]. The signal medium was used in
processing– this is the use of relays and electro-pneumatics as the source of the electrical

ISSN 2651-6691 (Print) | ISSN 2651-6705 (Online) | asianjournal.org

 Asian Journal of Multidisciplinary Studies
Vol. 2, No. 2, (2019)
ISSN 2651-6691 (Print)
ISSN 2651-6705 (Online)

signal Direct Current (DC). Operating voltage is development of a basic electro-pneumatic control
frequently used at 24 Volts (V). The working trainer which can be utilized for student
medium is compressed and filtered air which is practicum during laboratory time.
being measured by pounds per square inch (psi). This research output, a utility model, was
Solenoid actuation activates the ultimate control compact in design, very light and portable, which
valve. The valve reset is either by spring (Single can be transferred from one classroom to another.
Solenoid) or using different solenoid (Double This utility model also can be used for professors’
Solenoid Valve). More often, the pilot-assisted demonstration and for students’ laboratory
solenoid actuation achieves the valve activities performance and evaluation. It also
actuation/reset to decrease the valve size and reduced the time spent and problems associated
valued price [2]. Electro-pneumatic system with performing the activities repeatedly. With
control is carried out either using a combination the use of this utility model, students were able to
of relays and contactors. A relay is used on a understand and even learn more by way of
regular basis to convert input signals from actually performing such tasks or activities in
sensors and switches to a range of output signals regards to basic electro-pneumatics.
(normally closed or normally open). Signal
transmission can be done easily by relays and LITERATURE REVIEW
contactors combination. Eventually, the output In many fields industrial automation,
signals are transmitted to the solenoids which Electro pneumatics are used successfully.
trigger the final control valve which controls the Electro-pneumatic control systems power the
motion of various cylinders. The greatest manufacturing, assembly and packaging process
advantage of electro-pneumatics is the worldwide. In addition to technological
application of very effective proximity sensor advances, the change in requirements has had a
regulation of different types. [3]. significant impact on the appearance of controls.
The Pangasinan State University – The relay has been gradually replaced by the
Lingayen Campus, particularly the College of programmable logic controller in the signal
Technology offers the course entitled Bachelor of control segment in order to meet the increasing
Industrial Technology (BIT) with the nine (9) demand for more flexibility. To meet the needs of
major field of specialization of which three (3) of modern industrial practice, modern electro-
the major programs have an elective subject of pneumatic controls often implement new ideas in
Basic Electro-pneumatics, and these are the power section. The valve terminal, bus
Electrical Technology, Electronics Technology, network, and proportional pneumatics are
and Mechanical Technology. Ever since, the examples of this [4].
mode of delivering instruction in this subject, the Designing and developing a low-cost
basic electro-pneumatics, was purely lectured in electro-pneumatic automation trainer kit to be
nature considering the fact that this subject has a used as an instructional tool in Caraga State
laboratory unit component. As a result, students University’s teaching industrial control in
who took up this elective subject can visualize the engineering and electrical courses of could be a
electro-pneumatic applications through internet very feasible equipment to be used in the
videos and later, on their seminar and field trips industrial control laboratory courses as it serves
in the different industrial and manufacturing as a mock-up device to simulate the students’
companies. actual work. Because of the very expensive
In an effort to increase the quality of laboratory equipment, low-cost electro-
learning outcomes of the students of BIT pneumatic automation trainer kit has been used to
majoring in Electrical Technology, Electronics address the problem of inadequate training
Technology and Mechanical Technology, the facilities in SUCs, particularly in industrial
maker of this utility model seek learning control courses. In these classes, the low-cost
innovation which focused on the design and electro-pneumatic automation trainer kit provides

ISSN 2651-6691 (Print) | ISSN 2651-6705 (Online) | asianjournal.org

 Asian Journal of Multidisciplinary Studies
Vol. 2, No. 2, (2019)
ISSN 2651-6691 (Print)
ISSN 2651-6705 (Online)

quality training in the industrial control installation time, especially when using more
laboratory courses without the use of capital- contemporary, more compact assemblies such as
intensive and commercially available equipment. valve terminals. An additional goal of this utility
In many areas of low-cost automation, electro- model was to use relays and contactors to easily
pneumatics are widely used. Electro-pneumatic and rapidly modify open-and closed-loop control
system control is done either using the relays and policies. Extra purpose of this utility model was
contactors combination. Low-cost electro- to facilitate data exchange between multiple
pneumatic automation trainer kit provided control schemes.
Caraga State University with range of benefits
and advantages in successful student training. It MATERIALS AND METHODOLOGY
also benefits the administrator and instructors in The trainer board was 24 inches by 24
making improvised equipment to be used as inches by ¾ inch marine plywood. It was cost-
educational material and improving the school’s effective, space-efficient and portable. It
physical facilities. Most notably it offers the contained circuit breaker, plurality of din rails,
students for ability to use this equipment [5]. plurality of terminal blocks, plurality of relays
and relay holders, plurality of normality open and
closed push buttons, plurality of utility box,
Objectives of the Study
plurality of base plates, plurality of 24VDC 3/2
The primary objective of this research
way solenoid valves, plurality of 24VDC
was to design and develop a basic electro-
indicator lights, tubes duct, plurality of double-
pneumatic control trainer for use in learning
acting cylinders, plurality of clamps, and plurality
industrial control in BIT courses as an
of 24VDC proximity sensors. All the devices
instructional material.
were totally exposed for easy installation and
This study was intended to address the
familiarization.
issue of insufficient training facilities in State
A basic electro-pneumatic control trainer
Universities and Colleges due to the very costly
comprised of a 24 inches by 24 inches by ¾ inch
laboratory equipment, particularly in industrial
marine plywood (1) serves as a trainer board; a
control classes. Without the use of laboratory
din rail 1 (3) and a din rail 2 (25) were screwed to
equipment that is capital-intensive and
the said board and holds the circuit breaker (2)
commercially available in these grades, a basic
and plurality of solenoid valves (24) respectively
electro-pneumatic control trainer offers quality
for stability purposes; a circuit breaker (2) was
directions in the industrial control laboratory
attached to din rail 1 (3) and connected to a
classes.
24VDC power supply for protection of the
Another objective of this utility model
electrical circuit; a plurality of terminal blocks
was to provide a basic electro-pneumatic control
namely, terminal block 1 (4), terminal block 2 (9),
trainer that will allow the students to experience
terminal block 3 (14), terminal block 4 (17),
the actual wiring of the electrical circuit and
terminal block 5 (20), terminal block 6 (23),
performing the pneumatic control of a certain
terminal block 7 (26), terminal block 8 (31),
task as well as enhance students’ learning
terminal block 9 (36), terminal block 10 (41), and
experience and appreciation of the subject as well
terminal block 11 (48) were integrally attached to
as the course; and for the professors to assess the
the said with board, each terminal block includes
performance of their students. An additional goal
a plurality of terminal ports adapted to
of this utility model was to have greater reliability
interconnect each other; a plurality of utility box
owing to the reduced amount of mechanical
namely, utility box 1 (8), utility box 2 (13), and
components needed to move or subject to wear
utility box 3 (47) were screwed to the said board
and tear. Added purpose of this utility model was
and where the plurality of base plates namely, a
to have less planning and commissioning effort
base plate 1 (7), base plate 2 (12), base plate 3
and cost, especially for complex control. One
(46) were fixed respectively which acts as casing
more goal of this utility model was to have less

ISSN 2651-6691 (Print) | ISSN 2651-6705 (Online) | asianjournal.org

 Asian Journal of Multidisciplinary Studies
Vol. 2, No. 2, (2019)
ISSN 2651-6691 (Print)
ISSN 2651-6705 (Online)

of switches and pilot lights; a normally open push devices considering the hard to find and the high
button switch 1 (5) and normally closed push cost of the electro-pneumatic control
button switch 1 (6) were inserted at the base plate components. It was cable of handling an
1 (7) for stability purposes; a normally open push industrial-like electro-pneumatic control wiring
button switch 2 (10) and normally closed push installation, troubleshooting, and commissioning.
button switch 2 (11) were inserted at the base
plate 2 (12) for stability purposes; a green pilot Trainer Board Size 24 inches x 24 inches x ¾
light (43), a red pilot light (44), and an orange inch marine plywood
pilot light (45) were inserted at the base plate 3
(46) for stability purposes; a relay holder 1 (16), Weight (including 7 pounds
relay holder 2 (19), and relay holder 3 (22) were all devices)
attached to the said board which includes a Circuit Protection CB-3 Amperes
plurality of terminal ports and holds the relay 1 Din Rail Standard size
(15), relay 2 (18), and relay 3 (21) respectively Terminal Block 6 Terminals, 5 Amperes
for stability purposes; a plurality of solenoid Push Button Momentary Double
valves (24) which was electronically actuated Contact, 5Amperes
control valve, operatively connected to the Utility Box Standard size
plurality of proximity sensors as signaling means Base Plate ¼ inch Marine Plywood
and connected to a 60psi air compressor for air Utility box size
supply; a tube duct (27) attached to the said board Relay 24VDC holding coil - 8
which the pneumatic hoses ducted connecting the Pins
plurality of solenoid valves (24) going to plurality Relay Holder 8 Pins, 10 Amperes
of double acting cylinders for safeguarding; a Solenoid Valve 3/2 Way Valve, 100 psi
plurality of clamps namely, clamp 1 (32), clamp max, 24VDC
2 (37), and clamp 3 (42) were attached to the said Electrically Actuated
board and holds the plurality of double acting Pneumatic Tube 6mm diameter, 100 psi
cylinders namely, double acting cylinder 1 (28), max, color blue
double acting cylinder 2 (33), and double acting Wire Duct 25mm x 25mm, Standard
cylinder 3 (38) respectively for stability purposes; Double Acting 16mm diameter, 8mm
a plurality of double acting cylinders were Cylinder reach, 100 psi max
powered by compressed air having a Proximity Sensor 24VDC, 2mm sensing
corresponding operating piston which can be in capability
extend or retract position; a plurality of proximity Pilot Light 24VDC source
sensors namely, proximity sensor 1 (29) and Connecting Wire #18AWG, Stranded
proximity sensor 2 (30) were attached to double Wire
acting cylinder 1 (28), proximity sensor 3 (34)
and proximity sensor 4 (35) were attached to Table 1. Technical specifications of the basic
double acting cylinder 2 (33), and, proximity electro-pneumatic control trainer.
sensor 5 (39) and proximity sensor (40) were
attached to double acting cylinder 3 (38) which Methodology
serves as an actuating device for pre-determined This study utilized the developmental
sequential signaling by the said operating piston. type of research. A basic electro-pneumatic
The plurality of input and output devices control trainer comprised of:
terminals were pre-wired into the terminal blocks A 24 inches by 24 inches by ¾ inch
for faster installation and cost-effective for marine plywood (1) serves as a trainer board.
trainers’ maintenance purposes. It was equipped A din rail 1 (3) and a din rail 2 (25) were
with a low current circuit breaker to facilitate safe screwed to the said board and holds the circuit
operations and eliminate damages to all the

ISSN 2651-6691 (Print) | ISSN 2651-6705 (Online) | asianjournal.org

 Asian Journal of Multidisciplinary Studies
Vol. 2, No. 2, (2019)
ISSN 2651-6691 (Print)
ISSN 2651-6705 (Online)

breaker (2) and a plurality of solenoid valves (24) going to plurality of double-acting cylinders for
respectively for stability purposes. safeguarding.
A circuit breaker (2) was attached to din A plurality of clamps namely, clamp 1
rail 1 (3) and connected to a 24VDC power (32), clamp 2 (37), and clamp 3 (42) were
supply for protection of the electrical circuit. attached to the said board and holds the plurality
A plurality of terminal blocks namely, of double-acting cylinders namely, double-acting
terminal block 1 (4), terminal block 2 (9), cylinder 1 (28), double-acting cylinder 2 (33),
terminal block 3 (14), terminal block 4 (17), and double-acting cylinder 3 (38) respectively for
terminal block 5 (20), terminal block 6 (23), stability purposes.
terminal block 7 (26), terminal block 8 (31), A plurality of double-acting cylinders
terminal block 9 (36), terminal block 10 (41), and were powered by compressed air having a
terminal block 11 (48) were integrally attached to corresponding operating piston which can be in
the said with board, each terminal block includes extend or retract position.
a plurality of terminal ports adapted to A plurality of proximity sensors namely,
interconnect each other. proximity sensor 1 (29) and proximity sensor 2
A plurality of utility box namely, utility (30) were attached to double acting cylinder 1
box 1 (8), utility box 2 (13), and utility box 3 (47) (28), proximity sensor 3 (34) and proximity
were screwed to the said board and where the sensor 4 (35) were attached to double acting
plurality of base plates namely, a base plate 1 (7), cylinder 2 (33), and, proximity sensor 5 (39) and
base plate 2 (12), base plate 3 (46) were fixed proximity sensor (40) were attached to double
respectively which acts as casing of switches and acting cylinder 3 (38) which serves as an
pilot lights. actuating device for pre-determined sequential
A normally open push button switch 1 (5) signaling by the said operating piston.
and normally closed push button switch 1 (6) The basic electro-pneumatic control
were inserted at the base plate 1 (7) for stability trainer utilizes 24VDC as a power supply for the
purposes. electrical circuit which was connected to the
A normally open push button switch 2 circuit breaker (2) and a 60psi compressed air for
(10) and normally closed push button switch 2 pneumatic control as air supply which was
(11) were inserted at the base plate 2 (12) for connected to the plurality of solenoid valves (24).
stability purposes. The basic electro-pneumatic control
A green pilot light (43), a red pilot light trainer having a plurality of input and output
(44), and an orange pilot light (45) were inserted devices terminals were pre-wired into the
at the base plate 3 (46) for stability purposes. plurality of terminal blocks for faster installation
A relay holder 1 (16), relay holder 2 (19), and easy maintenance of the trainer.
and relay holder 3 (22) were attached to the said This research was limited to the
board which includes a plurality of terminal ports development of a basic electro-pneumatic control
and holds the relay 1 (15), relay 2 (18), and relay trainer. This utility model was further
3 (21) respectively for stability purposes. demonstrated following the instructional module
A plurality of solenoid valves (24) which in basic electro-pneumatics to the faculty
was electronically actuated control valve, members of the College of Technology,
operatively connected to the plurality of Pangasinan State University – Lingayen Campus
proximity sensors as signaling means and teaching BIT major in Electrical, Electronics and
connected to a 60psi air compressor for air Mechanical Technology. Additionally, interview
supply. and consultation with the faculty members to
A tube duct (27) attached to the said assess the functionality of the said utility model
board which the pneumatic hoses will be ducted was conducted.
connecting the plurality of solenoid valves (24)

ISSN 2651-6691 (Print) | ISSN 2651-6705 (Online) | asianjournal.org

 Asian Journal of Multidisciplinary Studies
Vol. 2, No. 2, (2019)
ISSN 2651-6691 (Print)
ISSN 2651-6705 (Online)

control valves that control the motion of different

cylinders and give the pilot lights a signal.
After demonstration, interview and
consultation with the faculty members of the
College of Technology, Pangasinan State
University – Lingayen Campus teaching BIT
major in Electrical, Electronics and Mechanical
Technology, the said utility model can perform
all the activities listed in the instructional module
in basic electro-pneumatics which were also
parallel to the real world industry of automation.
This research output was granted an
Industrial Design (ID) patent by the Intellectual
Property Office of the Philippines while still
Figure 1. Front view of the utility model, waiting for subsequent formality examination
which shows the design and its parts. report as a pending application for a Utility
Model (UM) patent by the same office.

Conclusion
Upon completion of this study, users can
learn how to read and comprehend pneumatic
circuit diagrams and acknowledge global norms,
acknowledge and comprehend pneumatic and
electrical parts and their features, build easy
electro-pneumatic circuits, read and comprehend
Figure 2. Perspective view of the utility model. circuit diagrams for electro-pneumatic controls,
Results and Discussion design circuits for multi-actuator control
Electro-pneumatic control incorporates schemes, comprehend feature, design, technical
electrical and pneumatic systems and was used information and symbols for pneumatic and
more commonly for big applications. The signal electronic sensors, include control circuit timer
medium was the electrical signal with a DC features, identify how electro-pneumatic
source in electro-pneumatics. Compressed air interfaces are interconnected, compare electro-
was the work medium. After completing this pneumatic alternatives in implementation and,
research, after installing and fixing various finally, schedule, design and produce practical
solenoid valves and components, providing training equipment.
electrical connections and regulating the pressure
of 60psi, the valves were found to execute the Recommendation
sequential order given through the pushbuttons. In this study, electro-pneumatic control
No short circuit was noted while operating on it system can be used in many applications,
in any of the electrical wirings. The voltages in automation can be simple even with complicated
operation were 24VDC. Solenoid actuation procedures, productivity can be increased that
triggered the final valve control. Electro- leads to a reduction in manufacturing time, errors
pneumatic system control was performed using a can be detected and fixed, After the interview and
relay combinations. Used either normally closed consultation to the faculty members of College of
or normally open relay to transform signal input Technology, Pangasinan State University –
from sensors and switches to the number of Lingayen Campus teaching BIT major in
output signals. The output signals were finally Electrical, Electronics and Mechanical
delivered to the solenoids that activate the final Technology, it was recommended that the design

ISSN 2651-6691 (Print) | ISSN 2651-6705 (Online) | asianjournal.org

 Asian Journal of Multidisciplinary Studies
Vol. 2, No. 2, (2019)
ISSN 2651-6691 (Print)
ISSN 2651-6705 (Online)

and operation of the electro-pneumatic control

system would have been much easier if the author
had used Programmable Logic Control (PLC) and
the scheme itself could be remotely controlled. So
the proposal was to use PLC that would be much
easier to monitor and simulate any control system
than to use other controllers because PLC is a
computer intended for industrial activities. As it
is simple to comprehend, the other
recommendation is to use Ladder diagram
language with PLC.

References

[1] Electropneumatic and PLC -

Electropneumatic and PLC 1.1
Introduction Electro pneumatics is now
commonly used in many areas of
Industrial low cost. (n.d.) Retrieved from
https://www.coursehero.com/fiel/22359
854/ Electropneumatic-and-PLC/
[2] WordPress.com. (n.d.) Retrieved from
https://mechanicalengineering120.files.
wordpress.com/2017/11/lecture-
41_electro-e28093-pneumatic-control
[3] Electrical Relay. (n.d.) Retrieved from
https://www.electronicstutorials.ws/io/io
_5.html
[4] Kanwar, G. J., Kumar, R., & Kumar, S.
(2015). Designing and Fabrication of
Electro-Pneumatic Trainer Kit.
International Conference of Advance
Research and Innovation, 59. Retrieved
from
https://www.ijari.org/assets/conf/icari-
2015-abstract.pdf
[5] Castillo, M. R. (2015). Low-Cost
Electro-Pneumatic Automation Trainer
Kit. International Journal of New
Technologies in Science and
Engineering, 2(6), 101-107. Retrieved
from
https://www.ijntse.com/upload/1450845
019206.pdf

ISSN 2651-6691 (Print) | ISSN 2651-6705 (Online) | asianjournal.org