FLUID POWER SYSTEM/ENGINEERING

Module-5
Pneumatic Control Circuits
 A pneumatic circuit consists of a variety of components, such as compressors, receivers,
filters, pressure regulators, lubricators, mufflers, air driers, actuators, control valves, and
conductors, arranged so that a useful task can be performed.
 In a pneumatic circuit the force delivered by a cylinder and the torque delivered by a
motor are determined by the pressure levels established by pressure regulators placed at
the desired locations in the circuit.
 Similarly, the linear speed of a pneumatic cylinder and the rotational speed of an air motor
are determined by flow control valves placed at desired locations in the circuit.

Direct control of single acting cylinder

 Pneumatic cylinders can be directly controlled by actuation of final directional control

valve. These valves can be controlled manually or electrically. This circuit can be used for
small cylinders as well as cylinders which operate at low speeds where the flow rate
requirements are less.

 When the directional control valve is actuated by push button, the valve switches over to
the open position, communicating working source to the cylinder volume. This results in
the forward motion of the piston rod. When the push button is released, the reset spring of

MOHAN G, ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL, SVIT, BANGALORE

 FLUID POWER SYSTEM/ENGINEERING

the valve restores the valve to the initial position. The cylinder space is connected to
exhaust port there by piston retracts due to spring or gravity.

Indirect control of single acting cylinder

Circuit diagram shown in figure. It is suitable for large single cylinders as well as cylinders
operating at high speeds. The final pilot control valve is actuated by normally closed 3/2
(Three-way Two-position) push button operated valve. The final control valves handle large
quantity of air.

 When the push button is pressed, 3/2 normally closed valve generates a pilot signal which
controls the final valve thereby connecting the working medium to blank end side or the
cylinder so as to advance the cylinder. Note that compressor and FRL units here in the
circuit are replaced by a simple triangle. A triangle or a circle with a center dot can be
used to represent air source in the pneumatic circuit design.
 When the push button is released, pilot air from final valve is vented to atmosphere
through 3/2 DCV. The signal pressure required can be around 1- 1.5 bar. The working
pressure passing through the final control valve depends on the force requirement which
will be around 6-10 bar. Single piloted valves are rarely used in applications where the
piston has to retract immediately on taking out the set pilot signal.

MOHAN G, ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL, SVIT, BANGALORE

 FLUID POWER SYSTEM/ENGINEERING

Direct control of Double Acting Cylinder

 As per the construction of double acting cylinder, there is no return spring in it. Hence the
spring forces are not available to it for retraction of the piston rod as it is in the case of a
single acting spring return cylinder.
 Here both the forward and return motions of the cylinder are controlled by air pressure
and hence a 4/2 DCV is used. Usually, when a double acting cylinder is not operated,
outlet `B' and inlet 'P' will be connected. In this circuit, whenever the push button is
pressed manually, the double acting cylinder will extend and retracts when the push
button is released.

Indirect control of double acting cylinder

 A double acting cylinder can be controlled indirectly using 4/2 pilot operated DCV. This
pilot operated valve may be termed as the main valve. The signal provided to the pilot
operated valve by means of an air impulse. This operation is therefore also called an
impulse operation.
 To control the main valve a 3/2 DCV or 2/2 DCV must be used. In the circuit shown in
figure, two DCVs are connected to a common air source. In the normal position the
cylinder will be in the retracted position. To extend the cylinder a pilot signal should be
sent to the main valve by actuating push button of the 3/2 DCV. When the push button is
released air flow from reservoir to actuator is disconnected, as a result the cylinder
retracts.

MOHAN G, ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL, SVIT, BANGALORE

 FLUID POWER SYSTEM/ENGINEERING

Speed control of cylinders

 It is always necessary to reduce the speed of cylinder from maximum speed based on
selected size of final control valve to the nominal speed depending on the application.
Speed control of Pneumatic Cylinders can be conveniently achieved by regulating the flow
rate supply or exhaust air.
 The volume flow rate of air can be controlled by using flow control valves which can be
either two way flow control valve or one way, flow control valve. This is also known as a
throttle valve or a flow restrictor.

There are two types of throttling circuits for double acting cylinders:

1. Supply air throttling

2. Exhaust air throttling

Supply air throttling

 This method of speed control of double acting cylinders is also called meter-in circuit. For
supply air throttling, one way flow control valves are installed so that air entering the
cylinder is throttled. The exhaust air can escape freely through the check valve of the
throttle valve on the outlet side of the cylinder. There is no air cushion on the exhaust side
or the cylinder piston with this throttling arrangement. As a result, considerable
differences in stroking velocity may be obtained even with very small variations of load
on the piston rod.
 Any load in the direction of operating motion will accelerate the piston above the set
velocity. Therefore supply air throttling can be used for single acting and small volume
cylinders.

MOHAN G, ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL, SVIT, BANGALORE

 FLUID POWER SYSTEM/ENGINEERING

Exhaust air throttling

 In exhaust air throttling flow control valves are installed between the cylinder and the
main valve in such a way that the exhaust air leaving the cylinder is throttled in both
directions of the motion of the cylinder.
 This method of speed control of double acting cylinders is also called meter-out circuit.
The supply air can pass freely through the corresponding check valves in each case. In this
case, the piston is loaded between two cushions of air while the cylinder is in motion and
hence a smooth motion of the cylinder can be obtained. The first cushion effect is due to
supply air entering the cylinder through check valve, and second cushion effect is due to
the exhaust air leaving the cylinder through the throttle valve at a slower rate. Therefore,
exhaust air throttling is practically used for the speed control of double acting cylinders.

Signal Processing Elements:

To meet the requirement of various conditions in pneumatic applications, signal processing
devices are often used. The following gates or valves are used, depending on the required
conditions.
1. OR Gate-Shuttle Valve-Used to select one of the two input signals.
2. AND Gate-Two Pressure Valve-To combine two input signals i.e. to satisfy two
conditions at the same time.
3. NOT Gate-3/2way, normally open, pilot operated Directional Control Valve-used to
negate the function.

MOHAN G, ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL, SVIT, BANGALORE

 FLUID POWER SYSTEM/ENGINEERING

OR Function

 The single acting cylinder in Figure can be operated by two input signals.
 If compressed air signal is applied to input X or input Y, will produce a signal at output Z.
 If there is no input signal, there is no output signal.
 If signals are present at both inputs, the signal with the higher pressure reaches the
cylinder.

 Two 3/2 push button actuated DCV's are connected to the inlet ports (X and Y) of the
shuttle valve. The output (Z) of the shuttle valve is connected to pilot port of the 3/2 DCV.
This in turn connected to the blank end side of the single acting cylinder. On pressing
either of the push buttons PB 1 or PB2 the compressed air will be delivered by the shuttle
valve to 3/2 DCV through the pilot signal. Pilot signal from the shuttle valve actuates the
DCV to allow the compressed air to the actuator inlet port. This results in extension of
cylinder.
 When the 3/2 push button valves return under spring pressure, they remove the pilot
pressure from the 3/2 pilot operated valve, it also retracts under spring pressure allowing
the valve to return to its initial position and exhaust the actuator as shown in the circuit
diagram. Examples include manual operations and applications relying on automatic

MOHAN G, ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL, SVIT, BANGALORE

 FLUID POWER SYSTEM/ENGINEERING

circuit signals, that is, when either control valve PB 1 or PB2 is operated, the cylinder will
work (extend or retract).
 One application of OR gate can be utilized in door closing of a CNC machine during
machining process. A double acting cylinder is used to open and close the door. One input
may be from the manual push button and another can be from the program itself. Here
both input signals are connected to a shuttle valve which in turn connected to the cylinder.
Door will be closed if any one input signal is present.

AND Function

 Another name for an AND function is interlock control. This means control is possible
only when two conditions are satisfied.
 A classic example is a pneumatic system that works only when its safety door is closed
and its manual control valve is operated. The flow passage will open only when both
control valves are operated. Fig. shows the circuit diagram of an AND function circuit.
The cylinder will work only when both valves PB1 and PB2 are operated.

MOHAN G, ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL, SVIT, BANGALORE

 FLUID POWER SYSTEM/ENGINEERING

The two pressure valve circuit is equivalent to the two input signaling devices connected in
series (PB 1 and PB2) one after the other (3/2 way valve, N/C). The signal output is passed all
the way through only if both signal elements are operated at a time.

In order to maintain a safe operating environment for the forming machine operator, the
forming machine that is shown in figure has to be operated by two push button valves at the
same time. Operation of the two push button valves causes the forming tool of an edge folding
device to fall down rapidly. If both or even just one push button is released the double acting
cylinder slowly returns to the initial position.

MOHAN G, ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL, SVIT, BANGALORE

 FLUID POWER SYSTEM/ENGINEERING

NOT Function

In order to hold or lock an operating conveyor or a similar machine, the cylinder must be
locked (extended) until a signal for cancelling the lock is received. Therefore, the signal for
cancelling the lock should be operated by a normally open type control valve.

MOHAN G, ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL, SVIT, BANGALORE