Pneumatics Part I

7/3/2009
Pneumatics Part‐I
Compressed air systems
By
Amaren P. Das
M.Tech (SYSCON) IIT‐B
• General methods of material handling
– Clamping , shifting, Positioning , Orienting
• General application
– Packing , Filling, Metering, Stacking , stamping etc.
• Machining and working
– Drilling , Milling, Forming, Sawing
D illi Milli F i S i
NFC TS 2009 Pneumatics APDas 2
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• Availability
– Everywhere, unlimited quantity
• Transport
– Easily be transported over pipelines over long distance
• Explosion proof
– No risk of explosion or Fire
• Cleanliness
– Un lubricated exhaust air are clean
• Speed
– Fast working medium …. Enables high working speed
– Temperature
– Insensitive to temperature fluctuations
• Preparation
– Dust and condensate should not be present
Dust and condensate should not be present
• Compression
– It is not always possible to achieve uniform and
constant piston speed with compressed air
• Force Requirement
– Pressure up to 8 bar only
p y
– Maximum force limited to, 40,000 to 50,000N
• Noise Level
– Exhaust air produce noise
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• Pneumatic control circuit
– Signal flow
– Symbols of hydraulic circuit
Symbols of hydraulic circuit
• Actuators
• Valves
– Direction control valve
– Flow control valves
– Pressure control valves
– Combination valve
Combination valve
• Air preparation (FRL units)
• Pumps
• Piping & distribution
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• How single acting cylinder works
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• How Double acting cylinder Works
• A single acting cylinder of 25
mm diameter is to clamp a
mm diameter is to clamp a
component when a push
button is pressed. As long as
the push button is pressed the
cylinder is to remain in the
clamped position . When the
push button is released the
clamp is retracted
l i t t d
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• A piston of a double acting
cylinder is to advance when
cylinder is to advance when
the 3/2 way roller leaver valve
1s2 is actuated and the push
button of 3/2 way valve 1S1 is
actuated. If either of the two is
released, then the cylinder
returns to initial position.
• How to do it with out using
and valve ?
• A double acting cylinder is to advance if one of the two push buttons
are pushed. If either of the push button is released the cylinder should
p p y
retract. The cylinder should also retract if it has completed its stroke.
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• What does the following circuit do ?
• The piston of a double acting
cylinder is to advance when a 3/2
y
way valve is manually pressed.
The cylinder is to remain
advanced until a second push
button is actuated, to move it to
initial condition. The signal from
the second PB can take effect
only when the signal from the 1st
PB has been removed. The
cylinder is to remain in the initial
li d i t i i th i iti l
position until a new start signal is
given. Speed of cylinder is to be
adjusted in both direction
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• A plastic component is embossed
using a die driven by a double
g y
acting cylinder. The die is to
advance and emboss the plastic
when a push button is operated.
The return of the die is effected
when a preset pressure is
reached. The embossing pressure
is to be adjustable.
• What changes are required if full
extension is also to be sensed ?
• A double acting cylinder is

used press together glued
components. Upon operation
of a push button, the clamping
cylinder extends.
• Once fully advanced position is
reached, the cylinder is to
remain for a time of T=6 sec
and then immediately retract to
the initial position. Cylinder
retraction is to be adjustable.
Anew cycle is only possible
after the cylinder is fully
retracted.
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• An actuator is an output device for conversion of
supply energy into useful mechanical work
supply energy into useful mechanical work
• Pneumatic actuators fall under two groups
– Linear motion
• Single acting cylinder
• Double acting cylinder
– Rotary motion
Rotary motion
• Air motors
• Rotary cylinders
• Single acting cylinder
– Si l
Single port
t
– Spring return
– Natural length of spring ‐>limited stroke length
– Compressed length of spring ‐>extra space
– Limited stroke 80mm
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• Two ports
• Cylinder can do work on both strokes
• Forces not equal
• When moving large mass, sudden stoppage at

th endd cause impact
the i t on the
th cylinder
li d cap, andd
damages it .
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• Tandem double acting cylinder
– Force on the piston is almost doubled
Force on the piston is almost doubled
• Through piston rod Cylinder
– Guide of cylinder is better, as both side
support is there
– Same force in both directions
• Multi‐position cylinder
– C
Consists of two or more double acting
i t ft d bl ti
cylinder, which are interconnected.
Three different principles are used for the construction of
y
rodless cylinders.
1. Band or cable cylinder
2. Sealing band cylinder with slotted cylinder barrel
3. Cylinder with magnetically coupled slide
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1. Cylinder barrel, seamless drawn tube
2. End cap
3. Bearing Cap
4. Piston rod
5. Seal ring, for leak tightness
6. Bearing bush, to guide the cylinder
7. Scraper ring , to keep dust away
• Force on the piston
Fth =A*P
A*P
Fth= force on piston
A= cross section area of piston
P = pressure on the piston face
Note: Effective piston force is less than the theoretical force
due to presence of friction. Under normal operating
condition (4 to 8 bar) friction force can be assumed as
10% of theoretical piston force
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• Area of Piston A= Area of piston cap side
– A=(3.14 * D2 / 4) A’ = Area of piston rod side
– A’=(D2 ‐ d2 )*3.14/4 P = working pressure
• Single acting FR= Friction force
– Feff= (A*P) ‐ ( FR + FF )
FF=Return spring force
• Double acting
D= Diameter of Piston
– Forward
Forward stroke
stroke
• Feff = A*P – FR d= Dia of rod
– Reverse Stroke
• Feff = A’*P – FR
• Length covered by the
piston from one end to
it f dt
other
• Stroke length should not
be greater the 2mt and
10mt for rodless cylinder
• Use buckling diagram for
Use buckling diagram for
long stroke
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• NBR (Nitrile Butadiene Rubber) Max service Temp 95C. Colour :Black. Ideally
suited for manufacturing all sealing components used in pneumatic and
hydraulic industry
hydraulic industry
• HNBR (Hydrogenated Nitrile rubber) Max service Temp. 150C. Colour: Black.
Similar to NBR but provides broader thermal and chemical resistance
• EPDM Rubber (EPM,EPR), Max Service Temp 150C. Color: Black. Incompatible
to mineral oil, but is resistant to many fluids that are incompatible with other
elastomers, including steam and break fluid.
• Viton. Max Service temp 200C, color: Brown. Outstanding chemical compatibility, low
compression set and broad temperature range, coupled with its ability to resist extrusion, tearing
and wear, makes this a significant compound
d k thi i ifi t d
• Silicone Rubber. Max Temp 200C. FDA approved for use in the food industry.
Silicones have poor wear, tear and tensile properties.
• Polyurethane . Max Temp 110C , 70C in water. Most popular, low compression
set and superior resistance to abrasion and tearing.
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• Converts pneumatic energy into
mechanical rotational energy
• Types
– Piston motors
• Clock wise and CCW, max
5000rpm, 1.5 to 20 kW
– Sliding vane motors
• Light weight, 3000 to 8500 rpm,
0.1 to 17 kW, used in hand held
tools
– Gear motors
• Up to 44KW
– Turbine motors
• Low power, very high speed
500,000 rpm, Ex. Dentist’s drill
• Direction control valve
• Non‐Return Valve
• Pressure control valve
• Flow control valve
• Combination valve
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• Direction control valve
– The direction control valve controls the
Th di i l l l h
passage of air signals by generating,
canceling or redirecting signals
• Input/signaling element : As signaling
element the DCV is operated for example , by
roller lever to detect the road position
• Processing element:
P i l t DCV redirects or cancels
DCV di l
signals depending on the signal input
• Control element: DCV must deliver the
required quantity of air to match the power
component requirement
– The valve is described by
• Number of ports : 2‐way, 3‐way, 4‐way , etc
• Number of position : 2 position, 3 position, etc
• Method of actuation of valve: mechanically actuate,
manually actuated, electrically actuated,
• Method of return actuation: Spring return , air Return ,
etc
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• Working line
ISO -5599-3
5599 3 Lettering System Port connection
1 P Pressure port
2, 4 A, B Working line
3, 5 R, S Exhaust port
Pilot lines
Applied signal stops flow from
10 z port 1 to port 2
Applied signal connects Port 1
12 P and 2
14 A, B Connects port 1 & 4

81, 91 R, S Auxiliary pilot air
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• Different types of actuation • Manual
– Manual
Manual
– Mechanical
– Pneumatic
– Electrical
– Combined
Mechanical
21

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Pneumatics Part I

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7/3/2009

• A double acting cylinder is

• When moving large mass, sudden stoppage at

14 A, B Connects port 1 & 4

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