Chapter 4

Compressed Air Systems

 Automation
– Human  Machine
– Use of machines, control systems and information
technologies to optimize productivity in the production of
goods and delivery of services
– An automatic operation or control of equipment, a process,
or a system
 Fluid
• A fluid is any material capable of flowing
(mechanical power – fluid power):
– compressed air
– hydraulic oil

• Pneumatic Systems - two main features:

– Pneumatic systems use compressed gas such as air
or nitrogen to perform work processes.
– Pneumatic systems are open systems, exhausting
the compressed air to atmosphere after use
 Pneumatic: Basic Principle
• Pneumatics is basically a method to turn
electricity into mechanical motion using
compressed gasses instead of motors or
electromagnets.
• Systems typically include an air
compressor, which stores compressed air
in a cylinder and release it under electric
control.
Applications
 Applications:
Pneumatic (vs hydraulic)
• Considerations:
– Weight
– Safety
– Accuracy
– Cleanliness
PASCAL'S LAW
• States that if pressure is applied to a non-flowing
fluid in a container, then that pressure is
transmitted equally in all directions within the
container.

PERFECT GAS LAW

• Express the relationships between pressure,
volume, and temperature.
– Boyle's Law - expresses the relationship
between pressure and volume when
temperature is held constant.
 Properties of Gases
Boyles Law
• “with constant temperature, the pressure of a
given mass of gas is inversely proportional to
its volume”, or:
p x V = constant
 Force and Pressure

P=F/A
• P is pressure
• F is force
• A is area
The SI unit for pressure is the pascal (Pa) and is equal to
one newton per square meter (N/m2)
 Normal air
• Pressure = 1 atmosphere (14.7 psi)
= 1.01352825 bar
= 101.352825 kPa

• Temperature = 20°

• Relative Humidity = 36%

 Compressed air
• Raised to a pressure above atmospheric pressure.
• Has potential energy to do work .
• In a real system,
– the compressed air will flow as the potential energy is
consumed (converted to kinetic energy).
– When there is flow in the system, the pressure begins
dropping.
– Proper sizing of all components (compressors, receiver
tanks (storage), piping, filters, regulators, lubricators,
control valves, and work devices) are required to minimize
loss of pressure and flow.
• All main pneumatic components can be
represented by simple pneumatic symbols.
• Each symbol shows only the function of the
component it represents, but not its
structure.
• Pneumatic symbols can be combined to
form pneumatic diagrams.
• A pneumatic diagram describes the relations
between each pneumatic component, that is,
the design of the system.
Elements of a Basic Compressed Air
Pneumatic System
A. Air Compressor
B. Check Valve
C. Accumulator
D. Directional Valve
E. Actuator
 Compressor
• Convert the mechanical energy from
motors and engines into the potential
energy in compressed air
• Pump that compresses air, raising air
pressure to above ambient pressure
for use in pneumatic systems
• Compressors can be divided into two
–Reciprocatory
–Rotary
 Pressure Regulating
Component (FRL)
• Formed by various components, each of which has its own pneumatic
symbol:
i. Filter – can remove impurities from compressed air before it is fed to
the pneumatic components.
ii. Pressure regulator – to stabilise the pressure and regulate the operation
of pneumatic components
iii. Lubricator – To provide lubrication for pneumatic components
 Valve
• One-way valve - allows pressurized air to
enter the pneumatic system, but prevents
backflow of air toward the compressor
when compressor is stopped (prevent loss
of pressure
 Accumulator
• Stores compressed air
• Prevents surges (sudden and strong) in
pressure
• Prevents constant compressor operation
(“duty cycles” of compressor)
 Directional Valve
• Controls pressurized air flow from
Accumulator (source to user equipment
via selected port
• Some valves are one way – shut tight
• Some valves are two way, allowing free
exhaust from the port not selected –
valves can be actuated manually or
electrically
 Actuator

• Converts energy stored in compressed air

into mechanical motion
• Example is a linear piston (piston limited
to moving in two opposing directions)
• Other examples are alternate tools
including: rotary actuators, air tools, etc.
• Some types of pneumatic actuators
include:
–Tie rod cylinders
–Rotary actuators
–Grippers
 Applications of pneumatic
system
• Dentists use pneumatics to operate drills.
• Carpenters use pneumatics to power air
hammers.
• Truckers use pneumatic brakes.
• NASA uses pneumatics to control the
operation of satellite launch vehicles.
• Conveyor system to transfer a part from one
station to another.
• Gating system.
 Advantages of Pneumatic System
(compared with hydraulic system)

• Energy consumption
• Cost
• Safety – do not burn when overheated
• One power source
• Low noise level
• Clean
• Operate at high speed
• Low component cost
• High effectiveness
• High durability and reliability
• Simple design
• High adaptability to harsh environment
• Environmental friendly
 Limitations
• Low accuracy – the volume of air may change
when compressed
• Low loading
• Processing of air before used – absence of
water vapour and dust
• Noise – release compressed air
 Control (Mechanical)
• Supply is refer to pneumatic (compressed air)
and hydraulic

• Can be divided into 2

– Direct control
– Indirect control
Direct control Indirect control
Actuator Actuator

Directional valve Directional valve

/switch
Switch
Supply

Supply
Example of direct control
Single acting
cylinder

Push button
returned by spring
NC 3/2 valve

FRL (supply)
Push button
returned by spring
NO 3/2 valve
Example of indirect control

With spring
Example of indirect control

Without spring
Pneumatic symbols
Actuators

33
 Switches
Return Spring (in fact not an Mechanical (plunger):
operator, but a built-in
element)

Roller Lever: one-way Roller Lever:

Manual operators: general: Lever:

Push Button: Push-Pull Button:

34
 Displacement-step diagram
• The displacement-step diagram and the
displacement-time diagram are used for
motion sequences.

• The displacement-step diagram

represents the operating sequence of the
actuators; the displacement is recorded in
relation to the sequence step.
 Time motion diagram
Phase

The sequence 1A+ 2A+ 1A-2A- is to be read as follows:

Cylinder 1A advances, cylinder 2A advances, cylinder 2A retracts, cylinder
1A retracts.
The signal for advancing is designated using a ‘+’ and the signal for retracting using a ‘-‘.
 Description of process
sequence:
1. If the limit switch 2S1 is actuated and the push button 1S1 is
pressed by the operator, the piston rod of cylinder 1A extends.

2. When the cylinder 1A reaches its forward end position, the limit
switch 1S3 is actuated and the piston rod of cylinder 2A
advances.

3. When the cylinder 2A reaches its forward end position, the limit
switch 2S2 is actuated and the piston rod of cylinder 1A retracts.

4. When the cylinder 1A reaches its retracted end position, the limit
switch 1S2 is actuated and the piston rod of cylinder 2A retracts.

5. When cylinder 2A reaches its retracted end position, the limit

switch 2S1 is actuated and the initial position is reached again.
 Time motion diagram

2 3 4 5=1
phase

A+ A- Cylinder A

B+ B- Cylinder B

Sequence: A+ B+ B- A-
• 2. Grouping

G1 G2
a1 b0
A+ B+ B- A-

st b1

e1 e2
a0
• A+ = x(G1)
• A- = b0(G2)
• B+ = a1(G1)
• B- = x(G2)
• e1 = st.a0(G2)
• e2 = b1(G1)
Time motion
diagram – cylinder

2 3 4 5
phase

A+ A- Cylinder A

B+ B- Cylinder B
Command signal – directional valve

2 3 4 5
phase
READY
START
TO
A+ STOP

A-

B+

B-
 Control signal – switches
Control chart - the switching status of the control element is represented in relation
to the steps or the time.

2 3 4 5
phase

start

a1

a0

b1

b0
 Cascade Group 2

L1/G1
L2/G2 c
e1 e2
 A a0 a1 B b0 b1

A+ A- B+ B-

c c c
b0 a1

L1/G1
c c
L2/G2 c
e1 e2

st b1

a0

All valves are normally closed

a0, b0 – left
a1, b1 - right