NITT/DPE/PRPC27/Lecture-17/kps@nitt.

edu

Pneumatic System
class -5

Electro Hydraulic /Pneumatic

system

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Overview of Electro Pneumatics

Electro Hydraulic/Pneumatic Products & Components

Electrical components combined with a Hydraulic/pneumatic

product are called as “Electro Hydraulic/Pneumatic
components”, and the product as an assembly is called as
Electro Hydraulic/Pneumatic product

Overview of Electro Pneumatics

Electro Hydraulic/Pneumatic Components
1. Actuators
• Solenoid
2. Sensors
• Magnetic sensors
• PE converter
• Pressure sensor
• Pressure switch

NOTE: Other widely used actuator in electrical circuits worldwide is

“relay”, which will be explained in the section “Electro
Hydraulic/pneumatic symbols & circuits”

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Electro Pneumatic products

Solenoid
1. Principle of a Solenoid coil
2. Applications
3. Technical information

Electro Pneumatic products

Solenoid
1. Principle of a Solenoid coil
When an electric current
flows through a conductor /
coil wounded on a Ferro
magnetic rod, EMF (Electro
motive force) will be induced
around the coil

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Electro Pneumatic products

Solenoid
2. Application of Solenoid coil
Used as actuators in
pneumatic / hydraulic
valves

Electro Pneumatic products

Solenoid
3.Technical information:
Voltage:
• The voltage source determines the coil winding to be used in
the appropriate solenoid.commonly DC and AC power supply
ratings are 12V,24V,48V,110V,220V
• AC vs.DC solenoids, AC solenoids are most Commonly used
in household appliances. Generally AC solenoids have been
specified when there is a high cost to rectify to DC
• AC Solenoids typically require twice the in rush power of an
equivalent DC solenoid. As a result, DC Solenoids are
chosen for many of today’s applications

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Electro Pneumatic symbols

Power source

JIS - Japanese Industrial Standards

IEC - International Electrotechnical Commission

Electro Pneumatic symbols

Input elements

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Electro Pneumatic symbols

Input elements

Electro Pneumatic symbols

Processing elements

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Electro Pneumatic Circuits

Example-1:Direct control of a single-acting cylinder

Control task: A single-acting cylinder is to extend when a push-button (PB) is pressed. The cylinder is
to retract when the PB is released. A 3/2-way single solenoid valve, rated for a coil voltage of 24 V DC,
controls the cylinder. Develop a pneumatic power circuit and an electrical control circuit to implement
the control task.

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Example-2: Direct control of a double-acting cylinder

Control task: A double-acting cylinder is to extend when a PB is pressed and to retract when the PB is
released. 5/2-way single solenoid valve controls the cylinder. Develop a pneumatic power circuit and
an electrical control circuit to implement the control task.

Electro Pneumatic circuits

Operation of a DAC using SR valve

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Electro Pneumatic circuits

Operation of a DAC using SR valve

Electro Pneumatic circuits

Operation of a DAC using SR valve

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Electro Pneumatic circuits

Operation of a DAC using SR valve

Electro Pneumatic circuits

Operation of a DAC using SR valve

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Electro Pneumatic circuits

Operation of a DAC using SR valve

Electro Pneumatic circuits

Operation of a DAC using SR valve

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Electro Pneumatic circuits

Manual operation of a DAC using SS valve

Electro Pneumatic circuits

Manual operation of a DAC using SS valve

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Electro Pneumatic circuits

Manual operation of a DAC using SS valve

Electro Pneumatic circuits

Manual operation of a DAC using SS valve

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Electro Pneumatic circuits

Manual operation of a DAC using SS valve

Electro Pneumatic circuits

Manual operation of a DAC using SS valve

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Electro Pneumatic circuits

Manual operation of a DAC using SS valve

Electro Pneumatic circuits

Manual operation of a DAC using SS valve

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Electro Pneumatic circuits

Manual operation of a DAC using SS valve

Electro Pneumatic circuits

Single cycle automation of a DAC

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Electro Pneumatic circuits

Single cycle automation of a DAC

Reed switch
Rating:30mA

Electro Pneumatic circuits

Single cycle automation of a DAC

Reed switch
Rating:30mA

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Electro Pneumatic circuits

Single cycle automation of a DAC

Reed switch
Rating:30mA

Electro Pneumatic circuits

Single cycle automation of a DAC

Reed switch
Rating:30mA

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Electro Pneumatic circuits

Single cycle automation of a DAC

Reed switch
Rating:30mA

Electro Pneumatic circuits

Single cycle automation of a DAC

Reed switch
Rating:30mA

Solenoids
Rating:200mA

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Electro Pneumatic circuits

Single cycle automation of a DAC

Reed switch
Rating:30mA

30mA 200mA

Solenoids
Rating:200mA

Electro Pneumatic circuits

Single cycle automation of a DAC

Reed switch
Rating:30mA

Warning !!!
30mA 200mA

Coil rating > reed switch rating

This will cause damage to the
reed switch
Solenoids
Rating:200mA

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Electro Pneumatic circuits

Explanation with a Real life scenario

For better understanding of the behavior of sensors

and coil in an electrical circuitry, we shall take a real
life example.
Eg., Weight lifting done by a man. Where, we relate
the terms in the example to the components in an
electrical circuit as shown below

Parameters Electrical circuit Weight lifting

Source Power supply Man

Medium Sensors / Wires Rope

Load Coil Weight

Electro Pneumatic circuits

Explanation with a Real life scenario

Condition:1; Source Kg < Load Kg; Week link – Source

Medium:
40Kg

Load 10Kg
20Kg
5Kg
5Kg
Source:
30Kg

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Electro Pneumatic circuits

Explanation with a Real life scenario

Condition:1; Result – Failure of source

Medium:
40Kg

Load
10Kg
20Kg
5Kg
5Kg Source:
30Kg

Electro Pneumatic circuits

Explanation with a Real life scenario

Condition:2; Medium kg < Load kg; Weak link - Medium

Medium:
30Kg

Load 10Kg
20Kg
5Kg
5Kg
Source:
40Kg

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Electro Pneumatic circuits

Explanation with a Real life scenario

Condition:2; Result – Failure of Medium

Medium:
30Kg

Load
5Kg
20Kg
5Kg
5Kg Source:
50Kg

Electro Pneumatic circuits

Explanation with a Real life scenario

Condition:3; Right Solution – Medium and Source > Load

Medium:
45Kg

Load 10Kg
20Kg
5Kg
5Kg

Source:
60Kg

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Electro Pneumatic circuits

Example: Problem Summary

Reed switch
Rating:30mA

30mA 200mA

Solenoids
Rating:200mA

Electro Pneumatic Circuits

Example: Problem Summary

To design a circuit in such a way that the current (I

amperes) carrying capacity of the source &
medium is always higher than that of the load

I in amps of medium
(or) I in amps of source > I amps load

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Electro Pneumatic circuits

Example: Solution
Incorporate relay in the circuit as shown below
Reed switch
Rating:30mA

30mA

200mA

Solenoids
Rating:200mA

Electro Pneumatic circuits

Example: Solution

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Electro Pneumatic circuits

Example: Solution

Electro Pneumatic Circuits

RELAY

• How does a relay work?

• Fundamentals of relay

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Electro Pneumatic Circuits

Relay
How does a relay work?
Lamp or Coil
Rating: 200mA
DC supply
NC

Relay contact C NO
Rating:3A
RELAY
Relay coil
Sensor
Rating: 30 mA
DC supply

Electro Pneumatic Circuits

Relay
Fundamentals of relay
A relay is an electrically operated switch.
Many relays use an electromagnet to
operate a switching mechanism, but other
operating principles are also used.

Relays find applications where it is

necessary to control a circuit by a low-
power signal, or where several circuits
must be controlled by one signal.

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Electro Pneumatic Circuits

Relay
Fundamentals of relay(continued)
A type of relay that can handle the high power required to
directly drive an electric motor is called a contactor.
Solid-state relays control power circuits with no moving parts,
instead using a semiconductor device to perform switching.

Relays with calibrated operating characteristics and sometimes

multiple operating coils are used to protect electrical circuits
from overload or faults; in modern electric power systems
these functions are performed by digital instruments still called
"protection relays".

Electro Pneumatic Circuits

Sockets
1. Plain socket
Standard sockets are used to protect the solenoid coil against
ingress of dust and water
2. Socket with LED and protection circuit
Condition: Source connected to the load directly
Whenever the coil is switched ON or OFF, there will be a
surge in current, which may lead to malfunctioning of the
source / load. To prevent this, LED sockets with protection
circuit is used.
NOTE: During ON or OFF, the surge current consumed by the coil will be
1.5 times higher than rated current, and then it settles to the rated current.
Therefore, the current rating of the Source and medium should be atleast
twice higher than the rated current of the load

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Electro Pneumatic Circuits

Sockets

3. Socket with LED

LED sockets are used just to confirm the presence of
electrical supply to the coil
This is recommended for machines / systems where separate
surge suppression circuit is already available

Electro Pneumatic products

Sensors

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Electro Pneumatic products

Magnetic sensor
1. Principle of a magnetic sensor
2. Applications
3. Technical information

Electro Pneumatic products

Magnetic sensor

The reed switch is an electrical switch operated by an applied

magnetic field. It was invented at Bell telephone laboratories in
1936 by W. B. Ellwood.

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Electro Pneumatic products

Magnetic sensor or Reed switch

How does a reed switch work?

• It consists of a pair of contacts on ferrous metal

reeds in a hermetically sealed glass envelope.
• The contacts may be normally open, closing
when a magnetic field is present, or normally
closed and opening when a magnetic field is
applied.
• Once the magnet is pulled away from the
switch, the reed switch will go back to its
original position

Electro Pneumatic products

Magnetic sensor or Reed switch
Electrical connection
2-wire reed switch

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Electro Pneumatic symbols

Electro Pneumatic
components and symbols

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Example 3: Relay control

Control task: A large volume double-acting cylinder is to be controlled by wing a 5/2-way single
solenoid valve. The cylinder is to extend when the PB is pressed and to retract when the PB is
released. Develop an electro-pneumatic control circuit to implement this control task.

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Example 4: Latching circuit

Control task: A double-acting cylinder is to be controlled using a 5/2-way single solenoid valve.
When push-button PBI is pressed, the cylinder is to extend and remain in that position even when
PBI is released. The cylinder is to retract to the home position when push-button PB2 is pressed.
Also, the cylinder is to remain in the home position even when PB2 is released. Develop an electro-
pneumatic control circuit with an electrical latching circuit as part of it.

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the main difference between the dominant-OFF and dominant-ON circuits

will be evident when both the 'Start' push-button (PBI) and the 'Stop' push-
button (PB2) are pressed simultaneously. In the first case, the circuit goes to
the 'OFF' state, hence the name 'dominant OFF' circuit. In the second case,
the circuit goes to the 'ON' state, hence the name 'dominant ON' circuit.

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