Electropneumatics
Electropneumatics
Chapter
ELECTRO-PNEUMATIC
CONTROL
Outlines
1. Introduction to Electro-Pneumatics
7. Review questions
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1. Introduction to Electro-Pneumatics
Definitions
Applications
Advantages / Disadvantages
Introduction to Electro-Pneumatics
Definitions
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Introduction to Electro-Pneumatics
Signal flow of a
Pneumatic power
system
Introduction to Electro-Pneumatics
Signal flow of an
Electro-Pneumatic
power system
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Introduction to Electro-Pneumatics
Pneumatic power section
Introduction to Electro-Pneumatics
Electrical signal control section
Solenoid valve
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Introduction to Electro-Pneumatics
Advantages of using Electro-Pneumatics
E-260
Electrical signal
input
(switch panel)
Push Button
Electrical symbols
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Example :
Normally Open (NO) and Normally Close (NC)
In pneumatic circuit :
For example : 3/2-way Push button (valve)
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(Electro-Pneumatic)
Mechanical Position sensor (Limit switch)
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Proximity switch
▪ Proximity switch contain a transistor
which conducts and switches (trigger
ON) when something comes near to
the sensors.
▪ Contactless actuated without
external mechanical actuating force,
including
o Magnetic proximity (Reed)
switch
o Inductive proximity switch
o Capacitive proximity switch
o Optical proximity switch
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switch
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Proximity
switch One-way
▪ Optical proximity switches use light barrier
optical and electronic means
for object detection.
▪ Three different types:
o One-way light barrier
Reflective
o Reflective light barrier light barrier
Diffuse reflective
optical sensor
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Proximity switch
Types Magnetic Inductive Capacitive Optical
Based on that
Based on
Based on current when an object It consists of a
magnetic field.
induced by bets near the light sensor,
Operation When a magnet is
magnetic fields to sensor, it changes which will be
Principle near the reed
detect nearby the. capacitance triggered by an
switch will be
metal objects between the object.
activated.
sensing elements.
Material
Magnet Metallic only All material All material
supported
Operating
<80mm <50mm <50mm 100mm
distance
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Proximity switch
Proximity switch
Question :
1. Name the switch type used for START and STOP button.
2. What is the different between A1 and A2 in Electrical circuit?
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Relay
Contactor
E-140
Coil
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▪ Signal control section of PLC control system is similar to that of relay control
system. The only difference is the controller (signal-processing block), in which the
relays are replaced by PLC
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Electrical Symbols
▪ In a circuit diagram the components are represented by graphical
symbols that are standardized according to DIN 40900.
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Electrical Symbols
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Electrical Symbols
Graphical symbols: manually
operated switching devices
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Electrical
Symbols
Graphical symbols:
electromechanical drives
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Electrical
Symbols
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Electrical Symbols
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Electrical Symbols
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3/2 DCVs
5/2 DCVs
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Solenoid DCV
▪ Solenoid valve is an electro-mechanical device that built-in with a
coil (solenoid) and a pneumatic Directional control valve.
▪ Directional control valve (DCV) solenoid operated use electrical
signals to control pneumatic valves.
▪ They are used to start, to stop and/or to change the direction of air
flow.
▪ There are 2 types operated of directional control valve using
solenoid:
o Directly operated valve
o Pilot operated valve
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The cross sectional view of 3/2 way single solenoid valve in the normal and
actuated positions are shown in Figure. In the normal position, port 1 is blocked and
port 2 is connected to port 3 via back slot (details shown in the circle) When the
rated voltage is applied to coil, armature is pulled towards the centre of the coil and
in the process the armatures is lifted away from the valve seat. The compressed air
now flows from port 1 to port 2, and ports 3 is blocked. When the voltage to the coil
is removed, the valve returns to the normal position.
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The cross section view of 5/2 way double solenoid in the normal and actuated
positions are shown in the Figure when the rated voltage is applied to coil 14, the
valve is actuated to a one switch in position with port 1 connected to port 4, port 2
connected to port 3, and port 5 blocked. When the rated voltage is applied to the
coil 12, the valve is actuated to the other switching position with port 1 connected
to port 2, port 4 connected to port 5 and port 3 blocked.
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Solenoid DCV
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Sample circuit
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Solenoid
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Logic operations
Signal storage
Delay
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Direct control
Direct control is the control of an electro-pneumatic valve without
using intermediate components such as a relay, a contactor or an
industrial computer (PLC). The valve solenoid is connected directly to
electric switch as shown in Figure.
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Indirect control
Indirect control is the control of an electro-pneumatic valve using
intermediate components such as relays, contactors or programmable
logic controllers (PLC).
Advantages of indirect control systems
•Remote control is possible
•Switching more than one valve at a time is
possible
•Latching is possible.
•Flexible design improvement and development.
•Incorporating logic operating conditions
(OR, AND conditions)
Logic operations
It is often necessary to combine signals from several control elements
through logic operations.
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Logic operations
It is often necessary to combine signals from several control elements
through logic operations.
Signal storage
▪ In the circuits that we have looked at so far, the piston rod only
advances if the input pushbutton is actuated. If the pushbutton is
released during the advancing movement, the piston rod is retracted
immediately, without having reached the forward end position.
▪ In practice, it is usually necessary for the piston rod to be fully
advanced, even if the pushbutton is pressed only briefly. To achieve
this, the DCV must remain in the actuated position when the
pushbutton is released; in other words, actuation of the pushbutton
must be stored.
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Signal storage
Manual forward and return stroke control with double solenoid DCV
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Signal storage
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Signal storage
Signal storage
▪ So far, the control signal is stored at final control element (position
of DCV position is maintained, even when the corresponding
solenoid is de-actuated) due to the nature of double solenoid DCV.
▪ In addition, the control signal can also be stored at signal processing
element, e. g. relay, using latching circuit.
Signal storage
using latching circuit
▪ Brief press “ON” pushbutton energies the coil K1, thus contact K1 closes.
▪ After “ON” pushbutton is released, relay K1 remains in the actuated position →
“ON” signal is stored at the relay.
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Signal storage
Signal storage
using latching circuit
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Signal storage
Manual forward and return stroke control via relay with latching function
▪ A relay with latching function combined with spring return DCV is
to be used for signal storage.
▪ When pushbutton S1 is pressed, the relay is latched. The DCV is
actuated via another relay contact and piston rod advances. When the
latching is released by actuation of pushbutton S2, the piston rod
retracts.
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Signal storage
Double solenoid DCV vs. latching circuit for signal storage
▪ Signal storage can be effected in the final control element (interface
between power section and signal control section) by means of a
double solenoid DCV, or alternatively, in the signal processing
element (signal control section) by means of a relay with latching
function.
▪ The various circuits behave differently in response to the
simultaneous presence of a setting and resetting signal, and in the
event of failure of the electrical power supply or a wire break.
Double Latching circuit combined with
Situation solenoid spring-return DCV
DCV Dominant ON Dominant OFF
Setting and resetting Valve position Valve moves to
Valve actuated
signal together unchanged neutral position
Failure of electrical Valve position Valve moves to Valve moves to
power supply unchanged neutral position neutral position
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Delay
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Displacement-step diagram
of the feeding device
▪ The program-controlled sequence is triggered when the operator presses the "START"
pushbutton. The sequence comprises the following steps:
o Step 1: The piston rod of cylinder 1A advances.
The workpiece is pushed out of the magazine.
o Step 2: The piston rod of cylinder 2A advances.
The workpiece is fed to the machining station.
o Step 3: The piston rod of cylinder 1A retracts.
o Step 4: The piston rod of cylinder 2A retracts.
▪ The "START" button must be pressed again to trigger another feed operation.
▪ The program-controlled sequence of motions of the feeding device is shown in the
displacement-step diagram. 71
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▪ In a relay circuit, the signals are combined with each other by the contacts of control
switches, pushbuttons and relays. The electronic proximity switches used here do
not have contacts; instead, they generate an output signal by means of an electronic
circuit.
▪ Each sensor output signal acts on the coil of a relay, which in turn switches the
necessary contact or contacts.
▪ If proximity switch 1B1 is tripped, for example, current flows through the coil of
relay K1. The related contacts switch to the actuated position. 74
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▪ When the piston rod of cylinder 1A reaches the forward end position, sensor 1B2
responds and contact K2 is closed. The second step of the sequence is activated.
Solenoid coil 2Y1 is actuated, and the piston rod of drive 2A advances.
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▪ When the piston rod of cylinder 2A reaches the forward end position, sensor 2B2
responds and contact K4 is closed. The third step of the sequence is activated.
Solenoid coil 1Y2 is actuated, and the piston rod of drive 1A retracts.
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Implementation procedure
Documentation
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Procedure for
developing a control system
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Implementation Procedure
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Implementation Procedure
Procedure for installing the control system
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Implementation Procedure
Programming a PLC
▪ If a programmable logic controller (PLC) is used, the motion
sequence of the pneumatic drives is determined by the program. The
basis for developing the PLC program is provided by either a
function diagram or a function chart. Program development can be
carried out concurrently with setting up the control system.
▪ Any program errors revealed in translation or during testing must be
corrected. The following program development steps must
subsequently be run through again. This process must be repeated
until all detectable errors have been eliminated.
▪ The final functional test for the program cannot be carried out until
the electropneumatic control system as a whole is commissioned.
When installation of the control system and program development is
completed, the program is loaded into the main memory of the PLC.
The electropneumatic control system is then prepared for
commissioning. 97
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Implementation Procedure
Programming a PLC
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Implementation Procedure
Commissioning
▪ Commissioning has three main purposes:
o Testing operation of the control system under all conditions occurring in
practice
o Carrying out the necessary settings on the control system (adjustment of
proximity switches, setting of throttles etc.)
o Correcting errors in the control system
▪ The pneumatic power section should initially be operated with
reduced supply pressure. This reduces the risk of personnel coming to
harm and/or the installation being damaged (for example if two piston
rods collide) if there are faults in the control system.
▪ To complete the commissioning procedure, the documentation must
be updated. This means:
o Entering current setting values
o Correcting circuit diagrams and terminal diagrams where appropriate
o If necessary, printing out the revised PLC program
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Implementation Procedure
Commissioning
Preparation for acceptance test certificate
▪ Once the control system is working faultlessly and the operator of the
control system is convinced that it is functioning properly,
development is completed. Handover of the control system from the
developer to the operator involves the following:
o The declaration of conformity
o Familiarization of maintenance and operating staff
o Handover to maintenance staff of the documents necessary for
maintenance, service and repair (see following Figure)
o Preparation of an acceptance test certificate to be countersigned by
the responsible developer and the operator of the control system
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Implementation Procedure
Commissioning
Preparation for acceptance test certificate
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Implementation Procedure
Commissioning
Maintenance, service and repair
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Documentation
▪ The set of documentation for an electropneumatic control system
comprises a range of documents:
o Function diagram or function chart (representation of the control
sequence)
o Pneumatic and electrical circuit diagram (representation of the
interaction of all components)
o Terminal allocation list (representation of the wiring allocation
of terminal strips in switchboxes and terminal boxes)
o Parts lists
o Positional sketch
▪ It is essential for the circuit diagrams and terminal diagram to be
available to the maintenance staff so that malfunctions and faults
can be quickly located and corrected. In many cases troubleshooting
is made easier if a function diagram or function chart, positional
sketch and parts lists are available. These records should therefore
be included with the documentation of each control system. 103
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Displacement-time diagram
▪ In a displacement-time diagram the movements of the piston rods are plotted as a
function of time. This form of representation highlights the different lengths of
time needed for individual steps.
▪ The displacement-time diagram for the sheet-metal bending device shows that
advancing the piston rod of cylinder 2A (step 2) takes considerably longer than
retracting it (step 3). 106
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Documentation
Function diagram
Advantages and Disadvantages
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Documentation
Sequential Function Chart (SFC)
(GRAFCET)
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Documentation
Structure of a SFC
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Documentation
Structure of a SFC
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Documentation
Structure of a SFC
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Documentation
Structure of a SFC
A transition in a SFC
▪ Transition from one step to the next does not take place until the
associated transition condition has been satisfied.
▪ In order to improve the overall clarity of the SFC, the transition
conditions are numbered. The numbering refers to the step and the
command whose acknowledgement is evaluated.
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Documentation
Structure of a SFC
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Documentation
Structure of a SFC
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Documentation
Structure of a SFC
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Documentation
Structure of a SFC
▪ The (right) Figure shows the SFC for the sheet-metal bending device
(left Figure). Four sequence steps are executed during one movement
cycle.
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Documentation
SFC
Advantages and Disadvantages
▪ As an aid to planning and troubleshooting, the SFC has the
following advantages:
o The mode of operation of the signal control section can be documented down
to the last detail.
o The key characteristics of a control system can be visualized in graphical form
(important especially when planning and documenting large control systems).
o The sequence-oriented structure makes it easy to determine when which step
enabling conditions are necessary and when which output signals are set.
o The finalized control system can be implemented at relatively low cost on the
basis of a detailed function chart.
▪ In relation to electropneumatic control systems, the major
disadvantage of SFCs is that the movement pattern of the drives is
not represented in graphical form. As a result, a SFC is less visually
clear than a function diagram. It is therefore often useful to prepare a
displacement-step or displacement-time diagram in addition to a
SFC. 117
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▪ Every component (apart from connection lines and connecting tubes) is identified by
identification code, enclosed within a frame, contains the following information:
o Unit number (digit; may be omitted if the entire circuit consists of one unit)
o Circuit number (digit, mandatory)
o Component identification (letter, mandatory)
o Component number (digit, mandatory)
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Unit number
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Circuit number
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Technical information
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Documentation
Electrical circuit diagram
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Documentation
Electrical circuit diagram
▪ An overview diagram provides an overview of the electrical
apparatus of a relatively large system, for example a packing machine
or an assembly unit. It shows only the most important
interdependencies. The various subsystems are shown in greater
detail in other diagrams.
▪ A function diagram illustrates the individual functions of a system.
No account is taken of how these functions are executed.
▪ A circuit diagram shows the details of the design of systems,
installations, apparatus etc. It contains:
o Graphical symbols for the items of equipment
o Connections between these items
o Equipment identifiers
o Terminal identifiers
o Other details necessary for tracing the paths (signal identifiers, notes on the
representation location)
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Documentation
Electrical circuit diagram
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Documentation
Electrical circuit diagram
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Documentation
Electrical circuit diagram
Electrical circuit diagram
of an electro-pneumatic control system
▪ In the circuit diagram of an electropneumatic control system the
graphical symbols of the components required to implement logic
circuits and sequences are entered consecutively from the top to the
bottom and from left to right. Relay coils and valve coils are always
drawn beneath the contacts.
▪ Other measures to ensure that a circuit diagram is easy to read
include:
o Division into individual current paths
o Identification of devices and contacts by letters and numbers
o Subdivision into a control circuit and main circuit
o Preparation of tables of contact elements
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Documentation
Electrical circuit diagram
Electrical circuit diagram
of an electro-pneumatic control system
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Graphical symbols
and terminal designations
for a relay
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Documentation
Electrical circuit diagram
Contact element table
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Documentation
Electrical circuit diagram
Contact element table
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Documentation
Electrical circuit diagram
Actuated contacts and sensors
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Task definitions
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7. Review questions
Closed-ended questions
Open-ended questions
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References
1. A. Esposito, Fluid power with applications, 7e, Pearson, 2014
2. P. Chapple, Principle of hydraulic systems design, 2e,
Momentum Press, 2015
3. Festo Didactic GmbH & Co
4. M.M. Abootorabi, Hydraulics & Pneumatics, Yazd University
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