UNIT

4
Introduction to and Components
of Pneumatic Systems
 CO related to
C602.1
chapter
List and draw components of hydraulic &
pneumatic systems with symbols and draw its
general layout.
C602.1
Describe working principle of various
components used in hydraulic & pneumatic
systems.
C602.3
Choose valves, actuators and accessories
required for simple hydraulic and pneumatic
 INTRODUCTIO
N
• Pneumatic technology deals with the study
of behavior 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.
General
layout
 General
• Air filters: These are used to filter out the contaminants
from the air. layout
• 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.
• Air cooler: During compression operation, air
temperature increases. Therefore coolers are used to
reduce the temperature of the compressed air.
• Dryer: The water vapor or moisture in the air is
separated from the air by using a dryer.
• Control Valves: Control valves are used to regulate,
control
and monitor for control of direction flow, pressure etc.
• Air Actuator: Air cylinders and motors are used to obtain
the required movements of mechanical elements of
pneumatic system.
DIFFERNCE
BETWEEN
 Selection of air compressors
for pneumatic circuits
• Air pressure required
• Free air delivery
required
• Space available
• Working environment
• Availability of space
 Piston
Piston compressors are
commonly used incompressor
pneumatic
systems.
The simplest form is single
cylinder compressor (Fig. 6.1.3).
It produces one pulse of air per
piston stroke.
As the piston moves down during
the inlet stroke the inlet valve
opens and air is drawn into the
cylinder.
As the piston moves up the inlet
valve closes and the exhaust valve
opens which allows the air to be
expelled.
The valves are spring loaded.
The single cylinder compressor gives
significant amount of pressure
Diaphragm
compressor
 Diaphragm
• compressor
These are small capacity compressors. In piston
compressors the lubricating oil from the pistons walls
may contaminate the compressed air.
• The contamination is undesirable in food,
pharmaceutical and chemical industries. For such
applications diaphragm type compressor can be used.
• Figure 6.2.1 shows the construction of
Diaphragm compressor.
• The piston reciprocates by a motor driven
crankshaft.
• As the piston moves down it pulls the hydraulic fluid
down causing the diaphragm to move along and the air
is sucked in.
• When the piston moves up the fluid pushes the
diaphragm up causing the ejection of air from the outlet
port.
• Since the flexible diaphragm is placed in between the
 Lobe
compressor
The lobe compressor is used
when high delivery volume but
low pressure is needed.
It consists of two lobes with one
being driven and the other
driving. Figure 6.2.5 shows the
construction and working of Lobe
compressor.
It is similar to the Lobe pump
used in hydraulic systems.
The operating pressure is
limited by leakage between
rotors and housing.
As the wear increases during
the operation, the efficiency
falls rapidly.
 Rotary vane type
compressor
The principle of operation of vane
compressor is similar to the hydraulic
vane pump. Figure 6.2.3 shows the
working principle of Rotary vane
compressor. The unbalanced vane
compressor consists of spring loaded
vanes seating in the slots of the rotor.
The pumping action occurs due to
movement of the vanes along a cam
ring. The rotor is eccentric to the cam
ring. As the rotor rotates, the vanes
follow the inner surface of the cam ring.
The space between the vanes decreases
near the outlet due to the eccentricity.
This causes compression of the air. These
compressors are free from pulsation. If
the eccentricity is zero no flow takes
place.
 Screw
pressures and relativelycompressor
Piston compressors are used when high
low volume of
air is needed.
The system is complex as it has many
moving parts. For medium flow and
pressure applications, screw compressor
can be used. It is simple in construction
with less number of moving parts. The
air delivered is steady with no pressure
pulsation. It has two meshing screws.
The air from the inlet is trapped
between the meshing screws and is
compressed. The contact between the
two meshing surface is minimum, hence
no cooling is required. These systems
are quite in operation compared to
piston type. The screws are synchronized
by using external timing gears.
 LINEAR
• These cylindersACTUA
produce TORS
work in one direction of
motion hence they are
named as single acting
cylinders.
• Figure 6.4.1 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 Figure
6.4.2. 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.
 Double acting
cylinder
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 with
•
cushioning
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. Figure
6.4.3 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.
 Cylinder with
•
cushioning
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
 Rotary actuator-Gear
motor
It consists of two inter meshing
gears inside a housing with one
gear attached to the drive shaft.
Figure 6.4.4 shows a schematic
diagram of Gear motor. The air
enters from the inlet, causes the
rotation of the meshing gear due
to difference in the pressure and
produces the torque. The air
exists from the exhaust port.
Gear motors tend to leak at low
speed, hence are generally used
for medium speed applications.
 Rotary actuator-vane
type
A rotary vane motor consists of a rotor with sliding vanes in the slots provided on the
rotor (Fig. 6.4.5). 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).
Rotary actuators-vane type
limited rotation
Rack and pinion type
motor
 FRL UNIT-AIR
FILTER
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 Fig.
6.3.2.
The thickness of sintered
cartridge provides random
zigzag passage for the air
to flow-in which helps in
arresting the solid
 FRL UNIT-AIR
FIL
The centrifugal action TER
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.
FRL UNIT-
REGULATOR
DECREASES
FRL UNIT-
LUBRICATOR
Application of pneumatic
system
 Advantages of pneumatic
(a)system
The advantages of pneumatic systems
(i) High effectiveness
(ii) High durability and reliability
(iii) Simple design
(iv) High adaptability to harsh
environment
(v) Safety
(vi) Easy selection of speed and pressure
(vii) Environmental friendly
(viii) Economical
 Disadvantages of pneumatic
system
• Relatively low accuracy
• Low loading
• Processing required before
use
• Uneven moving speed
• Noise