Level 1 Pneumatics Answers For Exercises

Pneumatics
Level 1
2012 MECHATRONICS International, Lichfield
Collection of
Answers for Exercises
2001 MECHATRONICS International Ltd, Lichfield
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in
any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written
permission of MECHATRONICS International Ltd.
Part No. MEX001
MECHATRONICS International Ltd

Unit 9, Lancaster Park, Newborough Road, Needwood,
Burton on Trent, Staffordshire, DE13 9PD, England
Tel: +44 (0) 1283 575444 Fax: +44 (0) 1283 575766
Web: www.mech.co.uk E-mail: admin@mech.co.uk

Answers: Assembly Fixture
1. Draw the symbol for a single acting cylinder, with spring return, according
to ISO 1219-1:
2. List two disadvantages of a single acting spring return cylinder:
Can only be used to do work in one direction of travel (that controlled

by compressed air).
Increased overall length due to the space required for the

compressed spring when the piston is extended.
Limited sizes available (stroke and bore) on standard units often the
maximum bore available is 100mm and maximum stroke is also
100mm (although specials are available from some companies but at
considerable premiums on price).
Unit cost is usually higher than double acting cylinder of same bore
and stroke, due to extra materials used (spring, etc), extra assembly
operations required, lower volume manufacture, etc.
3. Label the ports on the valve below, using the number system:
4. Convert the following pressures as required:
a) 6 Bar = 87 PSI
b) 72.5 PSI = 5 Bar

Answers: Date Stamping of Product
1. Draw the symbol for a double acting cylinder, with spring return, according
to ISO 1219-1:
2. Label the ports on the valve below, using the number system:
3. List three other ways of operating a 5/2 way directional control valve:
1) Foot pedal
2) Lever
3) Lever with detent
4) Air pilot
5) Solenoid (direct)
6) Solenoid (indirect, with air pilot)
4. Does a double acting cylinder deliver a greater force on the extend or

retract stroke and why ?
On the extend stroke due to force being developed by means of

applying pressure to an area and on the extend stroke the pressure is
applied to a greater area (the full face of the piston).

Answers: Bending Fixture
1. What does the number 12 on the 3/2 way pilot operated valve represent ?
The number identifies a pilot port, when a signal is applied to this

port the valve will switch to connect the supply port (1) with the
output port (2).
2. The black arrows drawn inside the squares of the 3/2 way valve symbols
indicate what ?
The direction which air is allowed to flow through the valve.
3. Draw the simplified symbol (to ISO 1219-1) for an Air Service Unit:
4. The single acting cylinder is fitted with a breather on the spring side, why ?
Without the breather the piston would not fully extend, due to the air
in the front chamber being trapped and as the piston extends this air
would then become pressurized. With the breather the air is allowed
to escape and then when the piston retracts air will be sucked into
the front chamber via the breather.

Answers: Panel Removal from a Jig
1. Draw the symbol, to ISO 1219-1, for a shuttle valve :
2. Show using a truth table its function :
1 1 2
0 0 0
1 0 1
0 1 1
1 1 1
3. Why cant check valves, as shown below, be used in place of the shuttle
valve ?
If check valves were used as per the diagram the cylinder would
never retract after its first extend movement, due to the check valves
would lock the air into the rear chamber of the cylinder.
4. Complete the symbol below for the shuttle valve and state whether there
will be an output available at 2, if yes, then what pressure would that
output be ?
There will be an output at 2 in this condition (both signals present)

the pressure available will be the higher of the two inputs and in this
case would therefore be 6 bar.

Answers: Product Separation
1. Describe, using standard pneumatic terminology, the valve shown below:
5/2 way directional control valve, double pilot actuated, (also

sometimes called a 5/2 way memory, 5/2 way bi-stable, or a 5/2 way
impulse valve).
2. With the valve shown what is the effect of:

a) Placing a signal (pressure) on port 14
The valve will switch to the left hand square and the supply port (1)
will be connected to the output port (4).
b) Placing a signal (pressure) on port 12
The valve will switch to the condition as shown and the supply port
(1) will be connected to the output port (2).
3. Directional control valves are listed by manufacturers as , , , etc,

what do these figures refer to ?
The size of the thread at the port of the valve, for the European
market these sizes are BSP (British Standard Pipe thread), which are
the standard threads. With the exception of M5 (5mm) all other
standard threads sizes are BSP. For the American market imperial
sizes are NPT (National Pipe Thread).
4. Do the push button valves used in the solution need to be of the same size
as the cylinder control valve, if not why ?
The push button valves used can be of a smaller size than the
cylinder control valve, this is because they are only used to apply
signals to the control valve and large volumes of air are not required
for this function, as the air is not travelling through the valve but into
an enclosed chamber and only sufficient air to switch the valve is
necessary.

Answers: Foundry Ladle Control
1. Draw the symbol, to ISO 1219-1, for a throttle/check (one-way flow control)
valve:
2. In the circuit below complete the symbol for the throttle/check valve so that
the cylinder will extend slower than normal:
3. Draw a circuit, using ISO 1219-1 symbols, showing how throttle/check

valves can be used, so that a single acting cylinder can extend and retract
slowly, with both directions of travel being independently adjustable:
4. With a double acting cylinder of a bore size of 25mm, or greater, would it

be better to slow down the piston speed with supply or exhaust air
throttling and why ?
It would be better to control the cylinder speed with exhaust air

throttling, this is due to the air would be controlled on its exit from
the cylinder and would have a braking effect on the cylinder
movement. If the cylinder is controlled by supply air throttling a
common problem is the cylinder will tend to run-away in an
uncontrolled manner, resulting in a jerky movement.

Answers: Barrier Control
1. Why can a throttle valve not be used in the supply to the 5/2 way control
valve instead of the throttle/check valves ?
If a throttle valve was used on the control valve supply, when it was
adjusted the speed of cylinder movement in both directions would be
affected, this is undesirable. It is beneficial to have independent
control of the cylinder speed in both directions of travel.
2. Show and alternative solution using a 5/2 way lever valve (with detent)
instead of the two 3/2 way push buttons, to give the same result:
3. Where should the throttle/check valves be situated in the circuit for the best
control of the cylinder ?
For best control the throttle/check valves should be situated as close

as possible to the ports of the cylinder, this means they are
controlling only the air in the cylinder and not the air in the
associated valves and pipework, thereby ensuring a better control.
4. Which throttle/check valve is controlling the barrier lowering speed

(cylinder extending) ?
The throttle/check valve shown on the right hand side of the circuit
diagram (the unit fitted in the front port of the cylinder).

Answers: Component Test Machine
1. What does the symbol below represent ?
This symbol represents a 3/2 way directional control valve, roller

actuated, spring return, normally closed type. The symbol is drawn
to represent the valve being operated and is therefore shown in its
switched (operated) condition.
2. How do these valves differ ?

Both symbols represent 3/2 way directional control valves,
a) is operated by means of a hand lever, with spring return
b) is operated by means of a hand lever, with detent (both positions

have to be manually selected).
3. Name two types of pneumatic counter:
1) Predetermined counter (a number is set on the counter and it

counts down from this number to zero).
2) Totalising counter (the counter starts at zero and simply counts

up).
4. How are pneumatic counters generally reset ?
By means of a signal (pneumatic) placed on the signal port of the

counter, a manual reset button is also generally incorporated.

Answers: Coldroom Door Control
1. What is the function of a shuttle valve ?
A shuttle valve is a double check valve but with only one seal (all
contained within one unit), it will allow either (or both) of two inputs
to become an output and at the same time close off the other input
path, so that it is not possible for the air to travel to exhaust. As it
will allow either or both inputs to become an output it is often called
an OR gate.
2. Where are shuttle valves required ?
Shuttle valves are required wherever two input signal lines join and
an output signal is required when either input signal is present.
3. Can a TEE be used instead of a shuttle valve, if not, why ?
A tee cannot be used to replace a shuttle valve, if it was the air from
either signal line would exhaust along the other signal line (air will
always take the path with the least resistance), the check valve
function within the shuttle valve avoids this problem.
4. Give another name for a shuttle valve:
OR gate.

Answers: Roof Ventilator Control
1. How is the valve represented by the symbol below described ?
The symbol represents a 5/3 way double pilot actuated directional

control valve with centre (neutral) condition all ports closed.
2. How is the centre (neutral) condition selected ?
The centre condition is automatically selected when neither of the

signals are present to switch the valve.
3. How do these valves represented by the symbols below differ ?
Both are 3/2 way push button operated, spring return valves but they
differ because
a) is of the normally closed type
and
b) is of the normally open type.
4. What could be a potential problem in the 2/2 way valve solution which
results in it being an unpopular solution for practical purposes ?
The solution utilising 2/2 way valves relies on a totally leak free
system for it to function correctly. If there are any leaks (no matter
how slight) then there will be movement on the cylinder, this would
obviously be undesirable and in some applications could be
dangerous. With the number of joints in the system it would be
difficult to guarantee a totally leak free system especially if the joints
are opened and remade after initial installation.

Answers: Product Sorting
1. Draw the symbol to ISO 1219-1 for a two pressure valve:
2. Show using a truth table its function:
1 1 2
0 0 0
1 0 0
0 1 0
1 1 1
3. Draw a circuit using ISO 1219-1 symbols where push buttons must be
operated to get an output signal but without the use of a two pressure
valve:
4. Complete the symbol below for the two pressure valve and state whether
there will be an output available at 2, if yes then what pressure would that
be ?
There will be an output at 2 in this condition (both signals present)

the pressure available will be the lower of the two inputs in this case
3 bar.

Answers: Machine Feed
1. What logic function is provided in the circuit by valves 1,5 and 1,6 ?
AND function.
2. If the circuit was run on continuous cycle, where would the cylinder stop
when the magazine runs out of components and why ?
The cylinder would stop in the retracted position due to the magazine
(component) register is in the signal line that generates an extend
signal, the retract signal would still be allowed to complete its
function.
3. If the circuit was to run when either 1,1 or 1,2 were operated instead of
both 1,1 and 1,2 what modifications would be required ?
The two pressure (AND) valve (1,4) would have to be changed for a
shuttle (OR) valve.
4. What disadvantage would the circuit have if all the valves 1,1, 1,2, 1,5 and
1,6 were placed in series ?
The signal feeding port 14 of valve 1,7 is now going through four
valves, which all get their supply from the one point and therefore
there is a distinct possibility that the strength of this signal when it
reaches valve 1,7 will only be very weak.
With the solution shown there is a better possibility of a strong signal

at valve 1,7 due to there being two main supplies and each one
travelling trough three valves. This is especially relevant where long
runs of pipe (or tubing) are to be utilised.

Answers: Product Cleansing
1. If a 3/2 way valve was not available for use at position 1,3 show how a 5/2
way valve could be used as a substitute:
2. Show how the cylinder speed can be effected by adjusting the exhaust flow
through the valve, instead of the air flow from the cylinder:
3. In the answer to 2 above, what is the name for the component being used
as an option to the throttle/check valve ?
(Exhaust Port) Throttle Valve.
4. With this application it may be difficult to mount the roller valves at the front
of the cylinder, therefore show (with a circuit using ISO 1219-1 symbols)
how a double acting cylinder with through rod can be used marking the
diagram to show where the roller valves are to be fitted:

Answers: Hopper Door Control
1. Draw the full symbol to ISO 1219-1 for a pneumatic timer valve of the
normally open type:
2. When does the timing start in this circuit/exercise ?

The timing starts from when the directional control valve is switched
to feed air to the rear of the cylinder due to the signal for the timer
valve being taken directly from the feed line of the cylinder.
3. If the requirement was for the timing to start only after the cylinder has
reached its fully outstroked position what other component is required and
where would it be mounted ?
A position register (e.g. roller valve) would be required at the end of

the cylinder stroke the output of this valve would then feed the signal
to the timer, this would ensure that the timing would not start until the
position register was actuated thus ensuring that the cylinder was at
the end of its stroke before a signal was applied to the timer.
4. What would be the effect on the set time delay if the system pressure:
a) Drops: The time delay would be increased over that originally

set.
b) Increases The time delay would decrease from that originally

set.

Answers: Clamping Fixture
1. Draw the symbol for a quick exhaust valve:
2. What would be the effect if a silencer was inserted in the exhaust port of
the quick exhaust valve and how do manufacturers often overcome this
situation ?
The exhaust noise would be reduced but at a sacrifice to the speed at

which the air is exhausted (the silencer acts as a restriction), to
overcome this situation one common method is to have the exhaust

port of the quick exhaust valve one size larger to accommodate a
larger silencer (e.g. On a ported quick exhaust valve the exhaust
port would be 3/8) also longer than standard silencers are
sometimes available (thus increasing the surface area and reducing
the restriction).
3. Where else in the circuit could the workpiece register (1,5) be placed, still
meeting with the original specification and without any detriment to the
application ?
The workpiece register would be placed in the circuit before the push
buttons 1,1 and 1,2 it would be supplied direct from the mains and its
output would feed the supply to the push button valves 1,1 and 1,2.
This would mean that for the cylinder to extend a workpiece must be
present and either of the push buttons can be operated.
4. Does it make any difference to the result if the valve 1,3 feeds 1,6 or vice
versa and why ?
It would make no difference to the operation of the circuit whether 1,3

feeds 1,6 or vice versa due to the valves being in series. However if
the roller was to feed the push button (1,6 feed 1,3) it would mean that
the input of the push button is live at all times that the drill is
registered, in certain applications this could be deemed unsafe.

Answers: Blister Pack Assembly
1. How do valves 1,3 and 1,5 differ ?
Both valves are timer valves 1,3 is of the normally open type and 1,5
is of the normally closed type.
2. What is the purpose of valve 1,3 in the circuit ?
Valve 1,3 being a normally open timer will close after a time delay
elapses, if the signal is maintained at port Z (10) of this valve for this
signal to be maintained the push button 1,1 is being held down. This
exercise specifically states that if the push button is held down that
the circuit is to complete one cycle and then stop this function is
provided by this timer valve which if switched will stop the start
signal from passing through.
3. What would be the effect if any of fitting valve 1,3 downstream of (after)
valve 1,4 ?
The timer valve would not come into operation due to the signal feed
being removed whenever the roller valve 1,4 was released (cylinder
extending) and therefore the valve 1,3 would be redundant and the
requirement of the circuit stopping after one cycle if the push button
is held down would not be achieved.
4. What would be the effect if any of fitting valve 1,5 upstream of (before)
valve 1,2 ?
The timer valve 1,5 if fitted before the roller valve 1,2 would be
permanently actuated due to its signal coming direct from the mains
supply, this valve would therefore become ineffective and the time
delay function would be lost the cylinder would retract immediately
that it reached the end of its stroke and actuated the roller valve.

Answers: Conveyor Selection
1. Why are the shuttle valves 1,5, 1,6, 2,5 and 2,6 used ?
The shuttle valves are used because the switching signals for the
directional control valves 1,7 and 2,7 can come in each case from
either of two points (from either of two push buttons).
2. What is it about the cylinders that creates the possibility of selecting 4

positions ?
4 Positions can be selected due to the fact that the two cylinders are
mounted back to back and one piston rod is mounted so that it
cannot move. The actual number of positions is dictated by the
number of cylinders and whether they are of the same or different
stroke lengths. Two cylinders of different stroke lengths will give 4

positions (2 positions for each cylinder).
3. If 3 positions were required what changes to the cylinders would be

required ?
The cylinders would both need to be of the same stroke length.
4. If 4 cylinders were mounted back to back and nose to nose (rod to rod)
how many different positions could be selected ?
Presuming that each cylinder is of a different stroke length then the

number of positions available for selection would be 16.
The number of positions is determined by each cylinder having 2

positions and the total number of cylinders becoming the power
therefore in this case the result is 2 to the power of 4 (24).

Answers: Lift and Transfer Station
1. What term is given to a sequence when the cylinders move in the same
order e.g. A+ B+ A- B- or A+ B+ C- A- B- C+ ?
These sequences are called repeat pattern sequences, the cylinders

repeat the same sequence of movements on each cycle if the
sequence of cylinder movements followed a differing pattern this is
known as a non-repeat pattern sequence.
2. If the package register was to stick in the operated condition what would
happen and why ?
The system would keep cycling once the air was turned on and the
only way to stop it would be to turn the air off (or get the package
register to switch off). This is due to the fact that a permanent supply
is present at the valve 1,2 so that each time this valve is actuated the
cycle starts again.
3. What is the purpose of valve 1,2 in this circuit ?
The valve 1,2 provides an interlock to ensure that the cycle of

operations must be completed before it is possible to start the next
cycle.
4. The lift cylinder (A / 1,0) is only required to do a job of work in the extend
(lift) mode why therefore is a single acting cylinder not used in this
application ?
Standard single acting cylinders would not be available in a long

enough stroke length.

Answers: Embossing Machine
(Circuit with idle return roller valves)
1. What is the name given to the valves 1,3 and 2,1 ?
3/2 way Idle return roller valve, normally closed type sometimes
called a one-way trip valve.
2. Why are valves 1,3 and 2,1 used ?
If normal roller valves were used in this circuit there would be

trapped signals created at port 12 of valve 1,4 (in the case of valve
1,3) and port 14 of valve 2,3 (in the case of valve 2,1) the use of idle
return roller valves eliminates this problem.
3. What do the arrows at position 2,1 (in relation to cylinder 1,0) and 1,3 (in
relation to cylinder 2,0) signify ?
These arrows show the direction of cylinder travel when the idle
return roller valve is actuated (the live direction) when the cylinder
travels in the opposite direction the idle return roller becomes
inoperative.
4. Give two disadvantages associated with the use of this type of valve:
1) The mounting position of the valve is very critical (more so than

with standard roller valves).
2) The roller is reset by means of a weak spring which always has the
potential of failing.
3) The speed of cylinder travel sometimes has to have slowed down

so that the idle return roller valve is actuated long enough for its
output signal to achieve its task with fast operating systems this
often means this type of valve cannot be used.
4) As the cylinder passes over the roller of the valve and then
releases it again at the end of its stroke this type of valve can be
difficult to fault find (due to cannot tell whether the valve has been
actuated or not).

(Latching circuit version)
1. Give an advantage of this solution over the roller version:
This solution uses standard roller valves and therefore suffers from
none of the potential problems associated with that type of valve.
2. What is the purpose of valve 1,3 in this circuit ?
Valve 1,3 is used to switch an air supply between two sections of the
circuit and thereby avoid trapped signals any signals that are likely
to result in a trapped signal situation are split by means of valve 1,3
so that they cannot both be live at the same time.
3. How does valve 1,2 differ from valves 2,1 and 2,2 ?
The valve 1,2 itself does not differ from valves 2,1 and 2,2 but it is
drawn in its actuated condition shown by the fact that the
connections are all made to the left hand square and the symbol
against the roller of the valve signifies the mechanical operation on
the valve.
4. What would happen in the event of the push button valve sticking in the
operated condition ?
If the push button was to stick a permanent signal is applied to the

control valve 1,4 (port 14) and the latching vale 1,3 (port 14) this
would mean that cylinder A (1,0) extends and remains extended at the
end of its stroke it actuates valve 2,1 which would send a signal to
valve 2,3 (port 14) switching this valve and extending cylinder B (2,0)
at the end of its stroke valve 2,2 is actuated this then causes trapped
signals at valves 1,3 and 2,3 the sequence will therefore stop at this
point.

(Cascade circuit version)
1. What do the following refer to in relation to a cascade circuit ?
a0 Limit switch (roller valve) situated at the instroke position of

cylinder A.
a1 Limit switch (roller valve) situated at the outstroke position of

cylinder A.
b0 Limit switch (roller valve) situated at the outstroke position of

cylinder B.
b1 Limit switch (roller valve) situated at the instroke position of

cylinder B.
2. What name is given to the 5/2 way valve drawn below the cascade group
lines (1 and 2) ?
Group selector valve.
3. Break the following sequence into groups for a cascade circuit ?
I II III IV
A+ B+ B- C+ C- B+ B- A-
4. Where else in the circuit could the start push button be placed and still
maintain the same result ?
The start push button may be installed in the line coming from
cascade group line 1 and feeding the signal port 14 of the control
valve for cylinder A. The result would be the same although the
group selector valve would be switched at the end of the cycle
whereas with the present system the group selector valve is not
switched until the start push button is operated.

Level 1 Pneumatics Answers For Exercises

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Level 1 Pneumatics Answers For Exercises

Uploaded by

Copyright:

Available Formats

Pneumatics

2001 MECHATRONICS International Ltd, Lichfield

Part No. MEX001

MECHATRONICS International Ltd

MECHATRONICS International Ltd

2. List two disadvantages of a single acting spring return cylinder:

Can only be used to do work in one direction of travel (that controlled

Increased overall length due to the space required for the

compressed spring when the piston is extended.

4. Convert the following pressures as required:

b) 72.5 PSI = 5 Bar

MECHATRONICS International Ltd

3) Lever with detent

6) Solenoid (indirect, with air pilot)

4. Does a double acting cylinder deliver a greater force on the extend or

On the extend stroke due to force being developed by means of

MECHATRONICS International Ltd

The number identifies a pilot port, when a signal is applied to this

The direction which air is allowed to flow through the valve.

MECHATRONICS International Ltd

2. Show using a truth table its function :

There will be an output at 2 in this condition (both signals present)

MECHATRONICS International Ltd

5/2 way directional control valve, double pilot actuated, (also

2. With the valve shown what is the effect of:

a) Placing a signal (pressure) on port 14

b) Placing a signal (pressure) on port 12

3. Directional control valves are listed by manufacturers as , , , etc,

MECHATRONICS International Ltd

3. Draw a circuit, using ISO 1219-1 symbols, showing how throttle/check

4. With a double acting cylinder of a bore size of 25mm, or greater, would it

It would be better to control the cylinder speed with exhaust air

MECHATRONICS International Ltd

For best control the throttle/check valves should be situated as close

4. Which throttle/check valve is controlling the barrier lowering speed

MECHATRONICS International Ltd

This symbol represents a 3/2 way directional control valve, roller

2. How do these valves differ ?

Both symbols represent 3/2 way directional control valves,

a) is operated by means of a hand lever, with spring return

b) is operated by means of a hand lever, with detent (both positions

3. Name two types of pneumatic counter:

1) Predetermined counter (a number is set on the counter and it

2) Totalising counter (the counter starts at zero and simply counts

4. How are pneumatic counters generally reset ?

By means of a signal (pneumatic) placed on the signal port of the

MECHATRONICS International Ltd

2. Where are shuttle valves required ?

3. Can a TEE be used instead of a shuttle valve, if not, why ?

4. Give another name for a shuttle valve:

MECHATRONICS International Ltd

The symbol represents a 5/3 way double pilot actuated directional

2. How is the centre (neutral) condition selected ?

The centre condition is automatically selected when neither of the

signals are present to switch the valve.

3. How do these valves represented by the symbols below differ ?

MECHATRONICS International Ltd

2. Show using a truth table its function:

There will be an output at 2 in this condition (both signals present)

MECHATRONICS International Ltd

With the solution shown there is a better possibility of a strong signal

MECHATRONICS International Ltd

(Exhaust Port) Throttle Valve.