1

PNEUMATIC
CONTROL
Introduction
 INTRODUCTION TO PNEUMATIC
CONTROL
CHAPTER 1
In Pneumatic control, compressed air is used as
the working medium, normally at a pressure from
6 bar to 8 bar. Actuation of the controls can be
manual, Pneumatic or Electrical actuation. Signal
medium such as compressed air at pressure of 1-
2 bar can be used [Pilot operated Pneumatics] or
Electrical signals [ D.C or A.C source- 24V – 230V ]
can be used [Electro pneumatics]
 Structure of
1

2 Pneumatic
3 Control System
4

A typical Pneumatic control system comprises of

the above groups of components. In direct actuation
controls signal processing group is not required. In
electro pneumatic Control signal processing can be
carried out using combination of relays and contractors
or using PLC. The final control valves are solenoid
actuated in the case of electro pneumatic controls
 Directional Control Valves
Directional Control valves are mainly used to change the direction of flow path of working medium or
signal medium. They are used for admitting or exhausting working medium to the cylinder or from the
cylinder for actuation of the cylinder. Also used to start or stop the pneumatic signal as well as for
signal processing

 Directional control valves are designated as per the following functions:

 
•Number of ports on the valves
•Number of switching positions
•Method of actuation
•Method of reset
•Design and constructional features
 
Symbolic Representation of Directional Control Valves
Symbolic Representation of Directional Control Valves 6
Method of Actuation and Reset/Return of Directional Control 7

Valves
Energy Elements 8
Designations of Symbols; Port Marking of Direction Control 9

Valve
 Controlling of Pneumatic Cylinders 10

Pneumatic cylinders can be controlled by the following methods:

1. Direct control of Single or Double acting cylinder
2. Indirect Control of Cylinder with Single Piloted Final Control Valve
3. Indirect Control of Cylinder with Double Piloted Final Control Valve
In the indirect control actuation, a pilot signal from a 3/2 N.C.
valve is used to activate pilot ports of final control valve.
Direct Control of Single Acting Cylinder 11

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 12

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.
Double Piloted Valve 13

Double piloted valve is also called as the Memory

valve
With the actuation of Forward push button, the out put signal
activates the set pilot port [14] of final control valve. This
results forward motion of the cylinder.
Now even if this push button is released the final control
valve remains in the actuated status as the both the pilot
ports are exposed to the atmosphere pressure and the
piston remains in the forward end position.
In order to retract the cylinder, the Return push button is
activated. This will convey reset signal from signal
source to the pilot port of final control valve [12] . The
piston retracts. Now even if the Return push button is
released the status of the cylinder will not change.
 
 Methods of Checking The End Positions 14

S1 The following methods are commonly used to

 
F=0 interrogate the end positions of piston in the cylinder:

1. Mechanically operated limit switches (Roller lever

4 2
14 12 or idle return roller type)
2. Reed sensors, either with electrical or pneumatic
5 1 3
output [the piston is incorporated with ring magnet]
2 2
3. Electrical proximity switches
S1 S2
4. Pneumatic Signal generators
1 3 1 3

 
Use of Limit Switches 15

S1 and S2 are the limit switches corresponding to home

position and extended position

•Although they are located in the path of the movement of

piston rod, normal practice is to represent the symbol of the
limit switches on either side of the final control valve with
out put signals connected to the pilot ports of the valve. The
limit switches of Roller lever type are essentially 3/2 way
ball seat or disc seat type of valves handling pneumatic
signals. These are available with direct actuation type and
internally pilot actuation type versions. Limit switches of
idle return roller type are used for actuation only in one
direction are used as signal elimination device in case of
signal overlap.

 
 Example 1 : Pin Feeding Device 16

Pins are to be fed from a hopper to the next

station one at a time using a Pneumatic Cylinder. Speed
of the cylinder should be adjustable both during forward
and return motion. The process of feeding should be
initiated using a detent push push button. Develop a
suitable Pneumatic control circuit .