Module 4

Introduction to Pneumatic Control

Pneumatic technology deals with the study of behaviour and applications of compressed air in
our daily life in general and manufacturing automation in particular. Pneumatic systems use air
as the medium which is abundantly available and can be exhausted into the atmosphere after
completion of the assigned task.

Basic Components of Pneumatic System

Important components of a pneumatic system are shown in fig.6.1.1.

a) Air filters: These are used to filter out the contaminants from the air.
b) Compressor: Compressed air is generated by using air compressors. Air compressors are
either diesel or electrically operated. Based on the requirement of compressed air, suitable
capacity compressors may be used.
c) Air cooler: During compression operation, air temperature increases. Therefore coolers are
used to reduce the temperature of the compressed air.
d) Dryer: The water vapor or moisture in the air is separated from the air by using a dryer.
e) Control Valves: Control valves are used to regulate, control and monitor for control of
direction flow, pressure etc.
f) Air Actuator: Air cylinders and motors are used to obtain the required movements of
mechanical elements of pneumatic system.
g) Electric Motor: Transforms electrical energy into mechanical energy. It is used to drive the
compressor.
h) Receiver tank: The compressed air coming from the compressor is stored in the air receiver.

The advantages of pneumatic systems

Pneumatic control systems are widely used in our society, especially in the industrial sectors
for the driving of automatic machines. Pneumatic systems have a lot of advantages.

• High effectiveness
Many factories have equipped their production lines with compressed air supplies and
movable compressors. There is an unlimited supply of air in our atmosphere to produce
compressed air. Moreover, the use of compressed air is not restricted by distance, as it can
easily be transported through pipes. After use, compressed air can be released directly into the
atmosphere without the need of processing.
• High durability and reliability
Pneumatic components are extremely durable and cannot be damaged easily. Compared to
electromotive components, pneumatic components are more durable and reliable.
• Simple design
The designs of pneumatic components are relatively simple. They are thus more suitable for
use in simple automatic control systems.
• High adaptability to harsh environment
Compared to the elements of other systems, compressed air is less affected by high
temperature, dust, corrosion, etc.
• Safety
Pneumatic systems are safer than electromotive systems because they can work in inflammable
environment without causing fire or explosion. Apart from that, overloading in pneumatic
system will only lead to sliding or cessation of operation. Unlike electromotive components,
pneumatic components do not burn or get overheated when overloaded.
• Easy selection of speed and pressure
The speeds of rectilinear and oscillating movement of pneumatic systems are easy to adjust
and subject to few limitations. The pressure and the volume of air can easily be adjusted by a
pressure regulator.
• Environmental friendly
The operation of pneumatic systems do not produce pollutants. The air released is also
processed in special ways. Therefore, pneumatic systems can work in environments that
demand high level of cleanliness. One example is the production lines of integrated circuits.
• Economical
As pneumatic components are not expensive, the costs of pneumatic systems are quite low.
Moreover, as pneumatic systems are very durable, the cost of repair is significantly lower than
that of other systems.
Limitations of pneumatic systems
Although pneumatic systems possess a lot of advantages, they are also subject to many
limitations.
• Relatively low accuracy
As pneumatic systems are powered by the force provided by compressed air, their operation is
subject to the volume of the compressed air. As the volume of air may change when compressed
or heated, the supply of air to the system may not be accurate, causing a decrease in the overall
accuracy of the system.
• Low loading
As the cylinders of pneumatic components are not very large, a pneumatic system cannot drive
loads that are too heavy.
• Processing required before use
Compressed air must be processed before use to ensure the absence of water vapour or dust.
Otherwise, the moving parts of the pneumatic components may wear out quickly due to
friction.
• Uneven moving speed
As air can easily be compressed, the moving speeds of the pistons are relatively uneven.
• Noise
Noise will be produced when compressed air is released from the pneumatic components.
Comparison of Hydraulic and Pneumatic systems

SI. No. Hydraulic System Pneumatic System

1. It employs a pressurized liquid It employs a compressed gas, usually

as a fluid air, as a fluid

2. An oil hydraulic system operates at A pneumatic system usually operates

pressures up to 700 bar at 5–10 bar

3. Generally designed as closed system Usually designed as open system

4. The system slows down when leakage Leakage does not affect the system

occurs much

5. Valve operations are difficult Valve operations are easy

6. Heavier in weight Lighter in weight

7. Pumps are used to provide Compressors are used to provide

pressurized liquids compressed gases

8. The system is unsafe to fire hazards The system is free from fire hazards

9. Automatic lubrication is provided Special arrangements for lubrication

are needed
Air treatment stages
For satisfactory operation of the pneumatic system the compressed air needs to be cleaned and
dried. Atmospheric air is contaminated with dust, smoke and is humid. These particles can
cause wear of the system components and presence of moisture may cause corrosion. Hence it
is essential to treat the air to get rid of these impurities. The air treatment can be divided into
three stages as shown in below figure.

In the first stage, the large sized particles are prevented from entering the compressor by an
intake filter. The air leaving the compressor may be humid and may be at high temperature.
The air from the compressor is treated in the second stage. In this stage temperature of the
compressed air is lowered using a cooler and the air is dried using a dryer. Also, an inline filter
is provided to remove any contaminant particles present. This treatment is called primary air
treatment. In the third stage which is the secondary air treatment process, further filtering is
carried out. A lubricator introduces a fine mist of oil into the compressed air. This will help in
lubrication of the moving components of the system to which the compressed air will be
applied.

Filters
To prevent any damage to the compressor, the contaminants present in the air need to be filtered
out. This is done by using inlet filters. These can be dry or wet filters. Dry filters use disposable
cartridges. In the wet filter, the incoming air is passed through an oil bath and then through a fine
wire mesh filter. Dirt particles cling to the oil drops during bubbling and are removed by wire mesh
as they pass through it. In the dry filter the cartridges are replaced during servicing. The wet filters
are cleaned using detergent solution.
Air filter and water trap is used to
• prevent any solid contaminants from entering in the system.
• condense and remove water vapor that is present in the compressed air.
The filter cartridge is made of sintered brass. The schematic of the filter is shown in the
above figure. The thickness of sintered cartridge provides random zigzag passage for the air to
flow-in which helps in arresting the solid particles. The air entering the filter swirls around due to
the deflector cone. The centrifugal action causes the large contaminants and water vapor to be flung
out, which hit the glass bowl and get collected at the bottom. A baffle plate is provided to prevent
the turbulent air from splashing the water into the filter cartridge. At the bottom of the filter bowl
there is a drain plug which can be opened manually to drain off the settled water and solid particles.

Lubricators

The compressed air is first filtered and then passed through a lubricator in order to form a mist
of oil and air to provide lubrication to the mating components. The above figure shows the
schematic of a typical lubricator. The principle of working of venturimeter is followed in the
operation of lubricator. The compressed air from the dryer enters in the lubricator. Its velocity
increases due to a pressure differential between the upper and lower changer (oil reservoir).
Due to the low pressure in the upper chamber the oil is pushed into the upper chamber from
the oil reservoir through a siphon tube with check valve. The main function of the valve is to
control the amount of oil passing through it. The oil drops inside the throttled zone where the
velocity of air is much higher and this high velocity air breaks the oil drops into tiny particles.
Thus, a mist of air and oil is generated. The pressure differential across chambers is adjusted
by a needle valve. It is difficult to hold an oil mixed air in the air receiver as oil may settle
down. Thus, air is lubricated during secondary air treatment process. Low viscosity oil forms
better mist than high viscosity oil and hence ensures that oil is always present in the air.

Pressure regulation
In pneumatic systems, during high velocity compressed air flow, there is flow-dependent
pressure drop between the receiver and load (application). Therefore, the pressure in the
receiver is always kept higher than the system pressure. At the application site, the pressure is
regulated to keep it constant.

The above figure shows the working of diaphragm type the outlet pressure is sensed by a diaphragm
which is preloaded by a pressure setting spring. If outlet pressure is too low, the spring forces the
diaphragm and poppet to move down thus opening the valve to admit more air and raise outlet
pressure. If the outlet pressure is too high the air pressure forces the diaphragm up hence reduces
the air flow and causing a reduction in air pressure. The air vents away through the load. At steady
state condition the valve will balance the force on the diaphragm from the outlet pressure with the
preset force on the spring.
Actuators
Actuators are output devices which convert energy from pressurized hydraulic oil or
compressed air into the required type of action or motion. In general, hydraulic or pneumatic
systems are used for gripping and/or moving operations in industry. These operations are
carried out by using actuators.
Actuators can be classified into three types.
1. Linear actuators: These devices convert hydraulic/pneumatic energy into linear motion.
2. Rotary actuators: These devices convert hydraulic/pneumatic energy into rotary motion.

The construction of hydraulic and pneumatic linear actuators is similar. However they differ at
their operating pressure ranges. Typical pressure of hydraulic cylinders is about 100 bar and of
pneumatic system is around 10 bar.

Single acting cylinder

These cylinders produce work in one direction of motion hence they are named as single acting
cylinders. The above figure shows the construction of a single acting cylinder. The compressed air
pushes the piston located in the cylindrical barrel causing the desired motion. The return stroke
takes place by the action of a spring. Generally, the spring is provided on the rod side of the
cylinder.
Double acting cylinder
The main parts of a hydraulic double acting cylinder are: piston, piston rod, cylinder tube, and end
caps. These are shown in the above Figure. The piston rod is connected to piston head and the other
end extends out of the cylinder. The piston divides the cylinder into two chambers namely the rod
end side and piston end side. The seals prevent the leakage of oil between these two chambers. The
cylindrical tube is fitted with end caps. The pressurized oil, air enters the cylinder chamber through
the ports provided. In the rod end cover plate, a wiper seal is provided to prevent the leakage of oil
and entry of the contaminants into the cylinder. The combination of wiper seal, bearing and sealing
ring is called as cartridge assembly. The end caps may be attached to the tube by threaded
connection, welded connection or tie rod connection. The piston seal prevents metal to metal
contact and wear of piston head and the tube. These seals are replaceable. End cushioning is also
provided to prevent the impact with end caps.

Cylinder end cushions

Double acting cylinders generally contain cylinder cushions at the end of the cylinder to slow down
the movement of the piston near the end of the stroke. The above figure shows the construction of
actuating cylinder with end cushions. Cushioning arrangement avoids the damage due to the impact
occurred when a fast-moving piston is stopped by the end caps. Deceleration of the piston starts
when the tapered plunger enters the opening in the cap and closes the main fluid exit. This restricts
the exhaust flow from the barrel to the port. This throttling causes the initial speed reduction.
During the last portion of the stroke the oil has to exhaust through an adjustable opening since main
fluid exit closes. Thus, the remaining fluid exists through the cushioning valve. Amount of
cushioning can be adjusted by means of cushion screw. A check valve is provided to achieve fast
break away from the end position during retraction motion. A bleed screw is built into the check
valve to remove the air bubbles present in a hydraulic type system.
Vane motor: a rotary actuator

A rotary vane motor consists of a rotor with sliding vanes in the slots provided on the rotor.
The rotor is placed eccentrically with the housing. Air enters from the inlet port, rotates the
rotor and thus torque is produced. Air is then released from the exhaust port (outlet).

Limited rotation actuators

It consists of a single rotating vane connected to output shaft as shown in below Figure. It is used
for double acting operation and has a maximum angle of rotation of about 270°. These are generally
used to actuate dampers in robotics and material handling applications. Other type of limited
rotation actuator is a rack and pinion type actuator.

Direct Control of Single Acting Cylinder

Pneumatic cylinders can be directly actuated by actuation of final control valve, manually or
electrically in small cylinders as well as cylinders which operates 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. When the push button is released, the
reset spring of the valve restores the valve to the initial position [closed]. The cylinder space is
connected to exhaust port there by piston retracts either due to spring or supply pressure applied
from the other port.

Indirect Control of Single Acting Cylinder

Large cylinders as well as cylinders operating at high speed are generally actuated indirectly
as the final control valve is required to handle large quantity of air. In the case of pilot operated
valves, a signal input valve [3/2 way N.C type, 1S1] either actuated manually or mechanically
is used to generate the pilot signal for the final control valve. 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 [4-6 bar]. Indirect control as permits processing of input signals. Single
piloted valves are rarely used in applications where the piston has t\\o retract immediately on
taking out the set pilot signal -. suitable for large single acting cylinders.