Unit 24: Applications of Pneumatics and Hydraulics

Unit code: J/601/1496 QCF level: 4 Credit value: 15

OUTCOME 2

TUTORIAL 1 – PNEUMATIC CIRCUTS

The material needed for outcome 3 is very extensive and the time required to study it in detail is more
than that normally allowed for a single module. This tutorial looks at the design requirements for
pneumatic circuits. This series of tutorials extends the work from outcome 2 to the construction of
complete circuits. You can complete more of this outcome by doing the assignments.

3 Be able to design pneumatic and hydraulic circuits

Pneumatic circuits: e.g. directional control, piloted control, reciprocating control, logic, memory,
multi-actuator circuits with sequential operation, cascading techniques, stepper circuits, pulsed
signals, latching circuits, direction and speed control of rotary actuators and air motors
Hydraulic circuit: e.g. sequential operation of multi-actuator circuits, regenerative circuits,
counterbalance circuits, ‘meter-in’ and ‘meter-out’ circuits, bleed-off circuits, direction and speed
control of hydraulic motors
Electro-pneumatic and electro-hydraulic circuit: use of electronic logic devices and systems and
their interface with fluid power circuits; solenoid valve arrangements
Emergency ‘fail safe’ circuit: use of emergency stop circuits to give predictable ‘parking’
positions for linear actuators, emergency stopping circuits for rotary actuators and motors, thermal
and pressure relief circuits, ‘fail safe’ circuit arrangements

 Describe further elements needed for controlling pneumatic circuits.

 Explain the advantages of pneumatics compared to other systems.

 Explain the classification of pneumatic components.

 Explain some of the basic principles of control systems.

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1. ADVANTAGES OF PNEUMATICS

Pneumatics is used in preference to hydraulics for the following reasons.

1. Easily connected to an air supply and needs no separate power pack.

2. The operation of actuators is fast.
3. No return piping is required; the air is vented to atmosphere.
4. Clean medium with no mess when it leaks.
5. No fire hazard as with oil.

Pneumatics is used in preference to electrics for the following reasons.

1. Will not start a fire through electric fault (Intrinsically safe).

2. Air motors are safe when over loaded and does not overheat.
3. Safer for operators (no risk of electrocution).

2. COMPONENT CLASSIFICATION

Pneumatic circuit elements are classed into four primary groups. These are

1. AIR SUPPLY AND CONDITIONING ELEMENTS such as

Compressor
Receiver
Pressure regulator,
Filter
Dryer
Lubricator

2. INPUT ELEMENTS (electrical or pneumatic) such as

On/off devices (switches)
Position sensors
Trip valves
Air jet sensors
Note many pneumatic sensing and switching devices are directional control valves such as a 3/2
plunger operated valve for detecting a cylinder position.

3. PROCESSING ELEMENTS such as

Logic valves (And Or and so on)
Time delay valves
Pressure switches
Directional control valves of many types.

4. ACTUATING DEVICES such as

Cylinders
Motors
Semi-rotary actuators

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Some elements are MONOSTABLE or BISTABLE.

A monostable element only has one stable position and automatically returns to it when the switching
signal is removed. Examples of these are

Directional valves with spring return

Pressure switches
Reed relays
Proximity detectors
Spring loaded switches.
Logic valves

A bistable element has two stable positions and requires a switching signal to change it from one to the
other. Examples are

Directional valves with no spring return such as

Pilot/pilot operation
Solenoid/solenoid operation
Valves with detents
Switches with no spring return
Latching relays
Fluidic logic elements (AND, OR and so on can be bistable)

Bistable elements are also memory devices since they retain their status until switched and so their
status indicates the last thing that happened to them.

3. ELECTRO-PNEUMATICS - SENSORS

The principles and symbols for electrically operated solenoid valves is covered in Outcome 2. In a
circuit using electric control, sensors are needed for elements of automatic control. In order to control
the movement of cylinders and mechanisms, sensors are fitted to provide a switching voltage when
they are at the operated position. These might be simple mechanically operated switches or micro
switches.

Figure 1

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Another form of detector is the magnetically operated reed
switch. These usually fit directly onto the cylinder with
suitable clips. The piston of the cylinder has a magnet built
into it and when the piston comes close to the reed switch,
the contacts close. The contacts on reed switches can only
take a small current so they are not suitable for directly
switching solenoids. Additional electronics is needed to do
this.

Figure 2
Another system uses proximity detectors.
These contain a transistor which conducts and
switches when something comes near them.
Some only work with steel but others work
with any material.

Another form uses light beams which are

reflected back when something comes near the
end and operates the transistor switch. The
LED is a useful aid. It lights up when the
proximity switch is activated. This helps when
tracing faults.
Figure 3

A similar sensor uses light beams and sensors. Often the light used in infrared. These sensors switch on
or off when the light beam is interrupted. These might be used for detecting an item passing on a
conveyor belt and activate a cylinder accordingly.

Figure 4
Switches and valves may be normally open (NO) or normally closed (NC).

Figure 5

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4. RELAYS

Some position sensors are able to switch high currents directly and may be hard wired to the solenoid
of a directional control valve. Most sensors (e.g. reed relays) would be damaged by high currents so
they have to be interfaced to the solenoids by relays. A relay is
used to to allow a small switch to operate and heavy duty switch.
The relay is mechanical switch and the contacts are moved by a
solenoid.

The output terminals may be normally open or normally closed. A

typical circuit diagram would show the arrangement of a sensor,
relay and output switch like this.
F
igure 6

Proximity detectors may be connected directly to computerised controllers but to switch solenoids
directly, it is safer to make them switch a relay unit and the relay switches the solenoids. The relay unit
may use the following symbols.

K is the relay solenoid and relay contact, S is the sensor switch

and Y is the valve solenoid. If something operates S1, k1 is
energised and relay contact k1 is closed and the solenoid Y1 is
energised thus operating the valve.

Figure 7
5. EUROPEAN LADDER LOGIC SYMBOLS

This diagram shows a solenoid operated directly by a sensor with no

relay.

Figure 8

This diagram shows a solenoid valve operated by a relay. The

relay is operated by the position sensor. The sensor contacts
may be normally open or normally closed.

Figure 9

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Here is a set of symbols for switches.

Figure 10

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 SELF ASSESSMENT EXERCISE No.1

Examine the pneumatic circuit below.

Circuit No.1

Write out an accurate description of each component.

A1. _______________________________________________________________________________

V1. _______________________________________________________________________________

Z1. _______________________________________________________________________________

V2/3. ______________________________________________________________________________

Items V1 and V3 are used to control the speed of the actuator. One uses “metering in” and one
uses “metering out”. Explain these terms and identify which does which.

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

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 Study the electrical circuit No.2. This is the circuit that will control the pneumatic circuit No.1. S
represents a switch, K represents a relay and Y represents a solenoid. If you have access to test ig
or simulation software, you should construct circuit and test it. You will need to select the
components correctly. You will need an electrical relay board and two proximity switches.

Circuit No.2

Explain the train of events that will occur after the 24 V supply is switched on.

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

Explain why the valve does not switch when the actuator is at half its rotation.

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

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 SELF ASSESSMENT EXERCISE No.2

The circuit below is designed for a press tool. When the guard is pulled down V3 is operated. If
V1 or item V2 is operated and V4 is not operated, the pressing operation is achieved by operation
of the cylinder (A1). When the press is fully operated, item V4 is pressed and the buzzer must
sound. After a small time delay the press is automatically raised.

Refer to the list of symbols and complete the identification chart below.

Item Name/Description Primary level

1,2, 3 or 4
Z1

Item Complete description Primary level Memory Device

1,2 ,3 or 4. Yes or No
A1

B1

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 Item Name/Ports/ positions/ Primary level Normally Open Memory Device
operation/ return 1,2 ,3 or 4. or Normally Yes or No
Closed
V1

V2

V3

V4

V5

V6

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