Matakuliah: Teknik Otomasi

Pneumatic Control System

Eka Maulana, ST, MT, MEng.
 What is Pneumatic?
 Pneumatics is a type of power transmission
that uses a gas ( in our case, air) and
pressure differential to create movement.
Pneu: udara bertekanan
 What can pneumatics do?
 Operation of system valves for air, water or chemicals
 Unloading of hoppers in building, steel making, mining & chemical
industries
 Lifting and moving in slab molding machines
 Crop spraying and operation of other tractor equipment
 Spray painting
 Holding and moving in wood working and furniture making
 Holding in jigs and fixtures in assembly machinery and machine tools
 Holding for gluing, heat sealing or welding plastics
 Holding for brazing or welding
 Forming operations of bending, drawing and flattening
 Spot welding machines
 Bottling and filling machines
 Wood working machinery drives and feeds
 Component and material conveyor transfer
 Pneumatic robots
 Pneumatic System
Air Production System Air Consumption System

5
 Advantages of Pneumatics
 Complete kit  Adjustable Force
 Weight  Different bore cylinders
change the available
equal or lighter than force
comparable alternatives  By adjusting the applied
 Simple pressure you can
instantly adjust the
Review the manual that force
comes with the  Durable
pneumatic kit and you’re No burned up motors – stall
ready to go with no damage
 Strong  Easy to expand
Force from 9 lbs to 180 once installed
lbs – easily adjustable
 Typical Valve
 Identification of the
component parts of a 8
7 9
typical 5/2 solenoid valve
with spring return 6
(Sub-base not shown)
 (1) Solenoid (15mm) 5
 (2) Piston
 (3) Spool with disc seals
 (4) Valve body 1

 (5) Return spring

 (6) Alternative ports 2, 4 2
 (7) Pressure indicator
 (8) Manual override 4 3
 (9) Electric connectors
 Style
 Style reflects the look of a
valve range as well as the
underlying design
principle. Examples are
Nugget, ISO Star and
Super X
 Type
 Type refers to the valves
installation arrangement
for example sub-base,
manifold, in line, and
valve island
 Design
 Design refers to the
principle of operation
around which the valve
has been designed, for
example, spool valve,
poppet valve and plate
valve
 Operators
 An operator is the
mechanism that causes a
valve to change state Push Shrouded Mushroom Twist
 They are classified as Button Button Button
manual, mechanical and
electrical

Switch Emergency Key Key Plunger Roller

Stop Released Operated

One Way Air Pilot Solenoid

Tip Pilot
 Actuator Control (3/2 valve)
 A 3 port valve provides
the inlet, outlet and
exhaust path and is the
normal choice for control
of a single acting cylinder
 In the normal position
produced by the spring,
the valve is closed 12
2
10
 In the operated position
produced by the push 3 1
button the valve is open
 The push button must be
held down for as long as
the cylinder is outstroked
 Actuator Control (3/2 valve)
 A 3 port valve provides
the inlet, outlet and
exhaust path and is the
normal choice for control
of a single acting cylinder
 In the normal position
produced by the spring,
the valve is closed 12
2
10
 In the operated position
produced by the push 3 1
button the valve is open
 The push button must be
held down for as long as
the cylinder is outstroked
 Actuator Control (5/2 valve)
 A five port valve provides
an inlet port 1 that is
switched between two
outlet ports 2 and 4 each
with an exhaust port 3 & 5
 In the normal position
produced by the spring 1
is connected to 2 with 4 4 2
14 12
to exhaust 5
 In the operated position 5 1 3
produced by pushing the
button port 1 is
connected to 4 with 2 to
exhaust 3
 Actuator Control (5/2 valve)
 A five port valve provides
an inlet port 1 that is
switched between two
outlet ports 2 and 4 each
with an exhaust port 3 & 5
 In the normal position
produced by the spring 1
is connected to 2 with 4 4 2
14 12
to exhaust 5
 In the operated position 5 1 3
produced by pushing the
button port 1 is
connected to 4 with 2 to
exhaust 3
Poppet Valves
 Poppet Valve 2/2
 The Poppet valve is a 12
simple and effective
design used mainly in 2/2
and 3/2 functions
 It has good sealing
characteristics and can
often be the choice for a
supply shut off valve
 A poppet seal has a butt
1 2
action against a raised
edged aperture
 Illustrated is a 2/2 air
operated poppet valve
 Poppet Valve 2/2
 The Poppet valve is a 12
simple and effective
design used mainly in 2/2
and 3/2 functions
 It has good sealing
characteristics and can
often be the choice for a
supply shut off valve
 A poppet seal has a butt
1 2
action against a raised
edged aperture
 Illustrated is a 2/2 air
operated poppet valve
 Poppet Valve 3/2
 Miniature 3/2 valve used
for generating signals
 The poppet seal will give
long life (not subjected to 3
sliding friction)
 Supply to port 1 assists
the spring to hold the
poppet shut 2
 Outlet port 2 is connected
through the plunger to a
plain exhaust port
1
 When operated exhaust
path sealed and poppet
opened (flow 1 to 2)
 Poppet Valve 3/2
 Miniature 3/2 valve used
for generating signals
 The poppet seal will give
long life (not subjected to 3
sliding friction)
 Supply to port 1 assists
the spring to hold the
poppet shut 2
 Outlet port 2 is connected
through the plunger to a
plain exhaust port
1
 When operated exhaust
path sealed and poppet
opened (flow 1 to 2)
 Poppet Valve 3/2
 Miniature 3/2 valve used
for generating signals
 The poppet seal will give
long life (not subjected to 3
sliding friction)
 Supply to port 1 assists
the spring to hold the
poppet shut 2
 Outlet port 2 is connected
through the plunger to a
plain exhaust port
1
 When operated exhaust
path sealed and poppet
opened (flow 1 to 2)
 Spool Valves
 A long standing popular
versatile design
 Available in most
functions 3/2, 3/3, 5/2, 5/3,
etc.
 Fully force balanced
 Wide range of styles,
sizes, operators and
mounting arrangements
 Suit a multiple range of
applications
 Spool Types
 A spool has a number of
major and minor
diameters called lands
and valleys
 The lands seal with the
valve bore and the valleys
connect valve ports to
control flow direction
 Dynamic seal type has
the seals on the spool
 Glandless type have no
sliding seals
 Static seal type has the
seals fixed in the valve
bore
 Disc Seals
 A disc seal is a loose fit in
the groove, with the outer
diameter just in contact
with the valve bore.
 Under differential
pressure the disc seal is
pushed sideways and
outwards to seal the
clearance between the
outer diameter of the
piston and the valve bore
 The slim profile gives low
radial force therefore
reducing friction
 Spool Valve (dynamic seals)
 This 5/2 valve has a spool fitted with disc seals
 The seals move with the spool therefore they are called
dynamic
 Normal position: port 1 is joined to 4 and 2 is joined to 3
 Operated position: port 1 is joined to 2 and 4 is joined to 5

4 2
14 12

1
5 3

14 12
5 4 1 2 3
 Spool Valve (dynamic seals)
 This 5/2 valve has a spool fitted with disc seals
 The seals move with the spool therefore they are called
dynamic
 Normal position: port 1 is joined to 4 and 2 is joined to 3
 Operated position: port 1 is joined to 2 and 4 is joined to 5

4 2
14 12

1
5 3

14 12
5 4 1 2 3
 Spool Valve (glandless)
 This 5/2 valve has a matched spool and sleeve. The fit is
so precise that seals between them are unnecessary
 The tiny amount of air crossing the spool lands provides
an air bearing
 The result is low friction and long life

4 2
14 12

5 1 3

14 5 4 1 2 3 12
 Spool Valve (glandless)
 This 5/2 valve has a matched spool and sleeve. The fit is
so precise that seals between them are unnecessary
 The tiny amount of air crossing the spool lands provides
an air bearing
 The result is low friction and long life

4 2
14 12

5 1 3

14 5 4 1 2 3 12
 Spool Valve (static seals)
 This 3/2 valve has a plain spool sliding within static seals
 The O Ring seals are held in carriers fixed in the valve bore
and positioned by spacers (not shown)
 The larger O Rings seal the valve bore with the carriers
 The smaller O Rings seal the carriers with the spool

2
2
12 10

3 1

12 10

3 1
 Spool Valve (static seals)
 This 3/2 valve has a plain spool sliding within static seals
 The O Ring seals are held in carriers fixed in the valve bore
and positioned by spacers (not shown)
 The larger O Rings seal the valve bore with the carriers
 The smaller O Rings seal the carriers with the spool

2
2
12 10

3 1

12 10

3 1
Other Valve Designs
 Pressure Switch (pneumatic)
 Relay to boost weak 2
12 10
signals
 Relay for a pneumatic 3 1
time delay
2
 When the signal at port 12 12 10
reaches about 50% of the
3 1
supply pressure at port 1,
the pressure switch
operates to give a strong
output signal at 2
 For time delays at any
pressure only the linear
12 10
part of the curve will be
used giving smooth 3 1
adjustment
 Pressure Switches
 Pressure applied at port 1 2
12 10
acting on the differential
annular areas holds the 3 1
spool to the left
 The weak or slowly rising
pressure of a signal
applied to port 12 needs
only to reach about 50% 3
of he pressure at port 1 to
operate the valve 12 1 2
 Port 1 is then connected
to port 2
 Removing the signal
allows the differential
force to reset the valve
 Pressure Switches
 Pressure applied at port 1 2
12 10
acting on the differential
annular areas holds the 3 1
spool to the left
 The weak or slowly rising
pressure of a signal
applied to port 12 needs
only to reach about 50% 3
of he pressure at port 1 to
operate the valve 12 1 2
 Port 1 is then connected
to port 2
 Removing the signal
allows the differential
force to reset the valve
 Pressure Switches (electrical)
 This fixed value example
uses a built in single Fixed
acting cylinder to operate
a standard changeover Adjustable
microswitch
 The operating pressure is
about 3 bar this needs to
overcome the combined
force of the cylinder and
microswitch springs
 Adjustable pressure
switches are also
available
 Logic “OR” Shuttle Valve
2
 An air signal given to
either the left hand port 1 2 1 1
or the right hand port 1
will result in an output at
port 2
 The sealing disc moves
across to seal the 1 1
exhaust signal line to 2
prevent loss of signal
pressure

1 1
 Logic “AND” Shuttle Valve
2 2
 A single air signal at
either of the ports 1 will 1 1 1 1
cause the shuttle to move ISO 1219-1 Popular old
and block the signal symbol symbol

 If a signals are applied at

2 2
both the left hand AND
right hand ports 1 only
one of them will be 1 1 1 1
blocked the other will be 2 2
given as an output at port
2
 If the pressures are not 1 1 1 1
equal the one with the
lowest pressure is
switched
 Flow Regulation
 By the use of flow
regulators the outstroke
speed and instroke speed
of a piston rod can be
independently adjusted
 Speed is regulated by
controlling the flow of air
to exhaust
 The front port regulator
controls the outstroke
speed and the rear port
regulator controls the
instroke speed
 Flow Regulator
 Uni-directional, line
mounted adjustable flow
regulator
 Free flow in one
direction
 Adjustable restricted
flow in the other
direction
 Flow Regulator
 Uni-directional, line
mounted adjustable flow
regulator
 Free flow in one
direction
 Adjustable restricted
flow in the other
direction
 Banjo Flow Regulator
 Designed to fit directly in
to cylinder ports, so
placing adjustment at the
appropriate cylinder end
 Two types:
 One to give conventional
flow restriction out of
the cylinder and free
flow in (as illustrated)
 The other type to give
restricted flow in to the
cylinder and free flow
out (not illustrated)
 Quick Exhaust Valve
 In some applications
cylinder speed can be
increased by 50% when
using a quick exhaust
valve
 When operated, air from
the front of the cylinder
exhausts directly through
the quick exhaust valve
 The faster exhaust gives
a lower back pressure in
the cylinder therefore a
higher pressure
differential to drive out
the piston rod
 Quick Exhaust Valve
 Port 2 is connected
2
directly to the end cover 1
of a cylinder
 Port 1 receives air from
the control valve 2
 Air flows past the lips of
the seal to drive the
cylinder
 When the control valve is
exhausted, the seal flips
to the right opening the 1
large direct flow path
 Air is exhausted very
rapidly from the cylinder
for increased speed
 Quick Exhaust Valve
 Port 2 is connected
2
directly to the end cover 1
of a cylinder
 Port 1 receives air from
the control valve 2
 Air flows past the lips of
the seal to drive the
cylinder
 When the control valve is
exhausted, the seal flips
to the right opening the 1
large direct flow path
 Air is exhausted very
rapidly from the cylinder
for increased speed
 Solenoid Valves
 Solenoid valves are
electro-pneumatic relays
 The state of an electrical
input controls the state of
a pneumatic output
 Solenoid valves are the
interface between
electronic control
systems and pneumatic
power
 Types are:
Direct acting
Pilot operated
Proportional
 Direct Acting Solenoid Valves
 Used for:
Nugget 30
Signal generation and
processing
Control of small bore
single acting cylinders Excel 15
 Single station sub-base
mounted
 Multi-station sub-base
mounted Excel 22
 Integrated to larger valves
to become solenoid pilot
operated valves
 15, 22, 32 represent the Excel 32
mm width of the valve
 Principle of operation
 The double poppet 3
2
armature is held by a
spring against the inlet 3 1

orifice sealing the supply

at port 1
 Outlet port 2 is connected
to exhaust port 3
 When the coil is
energised the armature is
pulled up closing the
exhaust orifice and
connecting the supply 2 1
port 1 to the outlet port 2
 Principle of operation
 The double poppet 3
2
armature is held by a
spring against the inlet 3 1

orifice sealing the supply

at port 1
 Outlet port 2 is connected
to exhaust port 3
 When the coil is
energised the armature is
pulled up closing the
exhaust orifice and
connecting the supply 2 1
port 1 to the outlet port 2
End