PNEUMATIC CONTROL
Mohamad Maaroff Bahurdin
019 4708987
2 Pneumatic Control
• Automation & Principle of Pneumatic
Diagram
5
• Basic Pneumatic Circuit
4
• Symbols and standards in pneumatics
3
• Components of a pneumatic system
2
• Characteristics and applications of
pneumatics
1
Contents
1 Characteristics and Applications
of Pneumatics
Pneumatics
• is the use of pressurized air to effect
mechanical motion.
• Commonly is used in industry.
• It also has applications in among other things,
dentistry, construction, and mining.
• Pneumatic power users need not worry about
hazardous leakages as the fuel is commonly just
air.
Pneumatic Control 4
Pneumatics in review
• Played an important role as a technology in the
performance of mechanical work.
• The technological progress made in material,
design and production processes has further
improved the quality and diversity of pneumatic
components and thereby contributed to their
widely spread use in automation.
Pneumatic Control 5
Pneumatics in review (cont.)
• The pneumatic cylinder has a significant
role as a linear drive unit, due to its
– relatively low cost
– ease of installation
– simple and robust construction
– ready availability in various sizes and stroke
lengths.
Pneumatic Control 6
Pneumatics in review (cont.)
• The pneumatic cylinder has the following
general characteristics:
– Diameters 2.5 to 320 mm
– Stroke lengths 1 to 2000 mm
– Available forces 2 to 45000 N at 6 bar
– Piston speed 0.1 to 1.5 m/s
Pneumatic Control 7
Pneumatics in review (cont.)
• Pneumatic components can perform the
following types of motion:
– Linear
– Swivel
– Rotary
Pneumatic Control 8
Pneumatic Application
• Some industrial applications employing
pneumatics are listed below:
– General methods of material handling:
• Clamping
• Shifting
• Positioning
• Orienting
• Branching of material flow
Pneumatic Control 9
Pneumatic Application
– General applications:
• Packaging
• Filling
• Metering
• Locking
• Driving of axes
• Door or chute control
• Transfer of materials
• Turning and inverting of parts
• Sorting of parts
• Stacking of components
• Stamping and embossing of components
Pneumatic Control 10
Pneumatic Application
Pneumatic Control 11
Pneumatic Application
Pneumatic Control 12
Pneumatic Application
• Pneumatics is used in carrying out
machining and working operations.
– For example:
• Drilling
• Turning
• Milling
• Sawing
• Finishing
• Forming
• Quality control
Pneumatic Control 13
Advantage of Pneumatic
Availability Air is available practically everywhere in unlimited
quantities.
Transport Air can be easily transported in pipelines, even
over large distances.
Storage Compressed air can be stored in a reservoir and
removed as required. In addition, the reservoir can
be transportable.
Temperature Compressed air is relatively insensitive to
temperature fluctuations.
This ensures reliable operation, even under
extreme conditions.
Pneumatic Control 14
Advantage of Pneumatic
Explosion Compressed air offers no risk of explosion or fire.
proof
Cleanliness Unlubricated exhaust air is clean. Any unlubricated
air which escapes through leaking pipes or
components does not cause contamination.
Components The operating components are of simple
construction and therefore relatively inexpensive.
Speed Compressed air is a very fast working medium. This
enables high working speeds to be attained.
Pneumatic Control 15
Disadvantage of Pneumatic
Preparation Compressed air requires good preparation. Dirt and
condensate should not be present.
Compression It is not always possible to achieve uniform and
constant piston speeds with compressed air.
Force Compressed air is economical only up to a certain
requirement force requirement. Under the normal working
pressure of 600 to 700 kPa (6 to 7 bar) and
dependent on the travel and speed, the output
limit is between 40 000 and 50 000 Newtons.
Noise level The exhaust air is loud. This problem has now,
however been largely solved due to the
development of sound absorption material and
silencers.
Pneumatic Control 16
Criteria for a working medium
• Choice of working media:
– Electrical current (electricity)
– Fluids (hydraulics)
– Compressed air (Pneumatics)
– A combination of the above
Pneumatic Control 17
Activity
1. Give another examples of pneumatic
application.
2. Is it suitable to use it at home i.e. home
appliance? Why?
Pneumatic Control 18
Criteria for a working medium
• Selection criteria for the working section:
– Force
– Stroke
– Type of motion (linear, swivelling, rotating)
– Speed
– Service life
– Safety and reliability
– Energy costs
– Controllability
– Storage
Pneumatic Control 19
Criteria for a control medium
• Choice of control media:
– Mechanical connections (mechanics)
– Electrical current (electrics, electronics)
– Fluids (hydraulics)
– Compressed air (pneumatics, low pressure
pneumatics)
Pneumatic Control 20
Criteria for a control medium
• Selection criteria for the control section:
– Reliability of components
– Sensitivity to environmental influences
– Ease of maintenance and repair
– Switching time of components
– Signal speed
– Space requirements
– Service life
– Modification of the control system
– Training requirements of operators and maintenance
personnel
Pneumatic Control 21
Pneumatics and control system
development
• The product development in pneumatics
can be considered in a number of areas:
– Actuators
– Sensors and input devices
– Processors
– Accessories
– Control systems
Pneumatic Control 22
Pneumatics and control system
development
• Factors in the development of pneumatic
control systems:
Reliability Interchangeability and
Ease of maintenance adaptability
Cost of spare parts Compact design
Assembly and connection Economic efficiency
Maintenance and repair Documentation
costs
Pneumatic Control 23
Structure and signal flow
Pneumatic systems consist of an interconnection of
different groups of elements.
Pneumatic Control 24
Structure and signal flow
• The primary levels in a pneumatic system
are:
– Energy supply
– Input elements (sensors)
– Processing elements (processors)
– Control elements
– Power components (actuators)
Pneumatic Control 25
Structure and signal flow
• The elements in the system are
represented by symbols which indicate
the function of the element.
Pneumatic Control 26
Pneumatic Control System
Pneumatic Control 27
Circuit Diagram
Pneumatic Control 28
Activity
• Define the terms below:
– Actuators
– Sensors
– Signal input / output
– Control diagram / element
Pneumatic Control 29
2 Components of a pneumatic
system
Components of a pneumatic system
Air generation
and
distribution
Power
Valves
components
Pneumatic Control 31
Air generation and distribution
• The compressed air should be adequately
calculated and made available in the
appropriate quality.
• Air is compressed by the air compressor and
delivered to an air distribution system in the
factory.
• Air service equipment is utilized to prepare the
air before being applied to the control system.
Pneumatic Control 32
Air generation and distribution
• Maximum operating pressure is 800-1000 kPa
(8 - 10 bar) but in practice it is recommended
to operate at between 500-600 kPa (5 and 6
bar) for economic use.
• Due to the pressure losses in the distribution
system the compressor should deliver between
650-700 kPa (6.5 and 7 bar) to attain these
figures.
Pneumatic Control 33
Air generation and distribution
• A reservoir (receiver) should be fitted to
reduce pressure fluctuations.
• The compressor fills the reservoir which
is available as a storage tank.
Pneumatic Control 34
Air Distribution System
Pneumatic Control 35
Air generation and distribution
• The air service unit is a combination of
the following :
– Compressed air filter (with water separator)
– Compressed air regulator
– Compressed air lubricator
• Known as FRL unit
Pneumatic Control 36
FRL Unit
Pneumatic Control 37
Valves
• To control the pressure or flow rate of pressure
media. Depending on design, these can be
divided into the following categories:
– Directional control valves
– Input/signaling elements
– Processing elements
– Control elements
– Non-return valves
– Flow control valves
– Pressure control valves
Pneumatic Control 38
Valves
Pneumatic Control 39
Power components
• Also called pneumatic actuator converts
energy into motion.
• Types of pneumatic actuators i.e.:
– Rotary actuators
– Pneumatic cylinder
– Grippers
– Rod less actuators
– Vacuum generators
Pneumatic Control 40
Pneumatic Actuator
Pneumatic cylinder
Grippers
Pneumatic Control 41
Activity
• Discuss about others power components.
Pneumatic Control 42
3
Symbols and standards in
pneumatics
Single-Acting Cylinder
• Compressed air is applied to only one
side.
• The piston rod side of the cylinder is
vented to atmosphere.
• Perform work in only in the advance
direction of travel.
• The piston rod is driven inwards by the
force of a built-in spring or by external
forces.
Pneumatic Control 44
Single-Acting Cylinder
Pneumatic Control 45
Double-Acting Cylinder
• Actuated in both directions with
compressed air.
• It can perform work in both directions of
movement.
• The force transmitted to the piston rod is
greater during the advance stroke than
during the return stroke.
Pneumatic Control 46
Double-Acting Cylinder
Pneumatic Control 47
Double Acting Cylinder (Cont.)
Double-acting cylinder with adjustable end-position
cushioning at both ends
Double-acting cylinder with double-ended piston rod
Double-acting rod less cylinder with adjustable end-
position cushioning at both ends (pneumatic linear
drive)
Pneumatic Control 48
Others Actuator
Gripper (external), double-acting
Vacuum generator
Suction cup
Pneumatic Control 49
Non-return and Flow Control Valves
• Non-return valves block the flow in one
direction and release it in the opposite
direction. A distinction is made between:
– Non-return valves
– Shuttle valves (OR)
– Dual pressure valves (AND)
– One-way flow control valves
– Quick exhaust valves
Pneumatic Control 50
Non-return and Flow Control Valves
Pneumatic Control 51
Pressure Control Valves
• Pressure control valves influence the
pressure or are controlled through the
size of the pressure. A distinction is made
between:
– Pressure regulating valves
– Pressure relief valves
– Pressure sequence valves
Pneumatic Control 52
Pressure Control Valves
Pneumatic Control 53
Switching Symbols for Valves
• Pneumatic components are normally
shown in the deenergized condition in
circuit diagrams.
• Valve switching positions are represented
by a square.
• The number of squares corresponds to
the number of switching positions.
Pneumatic Control 54
Switching Symbols for Valves
• Functions and modes of operation are
drawn inside the square:
– Lines indicate the flow paths.
– Arrows indicate the flow direction.
– Closed ports are represented by two lines
drawn at right angles to one another.
• The connecting lines are drawn outside
on the square.
Pneumatic Control 55
Switching Symbols for Valves
Pneumatic Control 56
Directional Control Valves
• Information about the type of valve can be
established from the following features:
– Number of ports
– Number of switching positions
– Port numbering
• The following applies to the numbering of the
ports:
– Air supply port 1
– Exhaust ports 3, 5
– Working or outlet ports 2, 4
Pneumatic Control 57
Directional Control Valves
Pneumatic Control 58
Directional Control Valves
Pneumatic Control 59
Types of DCV actuation
• The following information is required in
order to fully represent a directional
control valve in a pneumatic circuit
diagram:
– Basic type of valve actuation
– Reset method
– Pilot control (if applicable)
– Additional forms of actuation (such as
manual override, if available)
Pneumatic Control 60
Types of DCV actuation
Pneumatic Control 61
Types of DCV actuation
Pneumatic Control 62
Other graphical symbol
Pneumatic Control 63
Other graphical symbol
Pneumatic Control 64
Applications and symbols DCV
Pneumatic Control 65
Applications and symbols DCV
Pneumatic Control 66
Safety requirements
• Dangers and protective measures
• One source of danger is moving parts of
machines and equipment.
• On a pneumatic press, for example, care
must be taken to prevent the operator's
fingers or hands from being trapped.
Pneumatic Control 67
Safety requirements
Pneumatic Control 68
4 Basic Pneumatic Circuit
Arrangement of graphical symbols
• The layout of a pneumatic circuit
diagram, the arrangement of the
graphical symbols and the identification
and numbering of the components are
standardized according to DIN/ISO 1219-
2.
Pneumatic Control 70
Arrangement of graphical symbols
• the symbols are arranged in the circuit
diagram as follows:
– Power components at the top
– Beneath those, valves with an influence on
speed (such as flow control valves, non-
return valves)
– Beneath those, control elements (directional
control valves)
– Power supply at the bottom left
Pneumatic Control 71
Positions of cylinders and DCV
• All components in a pneumatic circuit
diagram are represented
• The cylinder drives are in the initial
position.
Pneumatic Control 72
Positions of cylinders and DCV
Pneumatic Control 73
Identification code for components
• Every component (apart from connection lines
and connecting tubes) is identified in
accordance
• The identification code contains the following
information:
– Unit number (digit; may be omitted if the entire
circuit consists of one unit)
– Circuit number (digit, mandatory)
– Component identification (letter, mandatory)
– Component number (digit, mandatory)
Pneumatic Control 74
Identification code for components
• The identification code should be
enclosed within a frame.
Pneumatic Control 75
Unit number
• If there are several units pneumatic
control systems in a particular plant, the
unit number helps to clarify the
assignment between circuit diagrams and
control systems.
Pneumatic Control 76
Circuit number
• Preferably all components belonging to
the power supply should be identified by
circuit number 0. The other circuit
numbers are then assigned to the various
control chains (= circuits).
Pneumatic Control 77
Component identification and number
• Every component in a pneumatic control
system is assigned a component
identification and a component number
in the circuit diagram. Within each
circuit, components with the same
component identification are numbered
consecutively from the bottom to the top
and from left to right.
Pneumatic Control 78
Component identification and
number
Pneumatic Control 79
Technical information
• In order to facilitate assembly of a
control system and the replacement of
components when carrying out
maintenance, certain components in a
pneumatic circuit diagram are identified
by additional information.
Pneumatic Control 80
Technical information
• Cylinders:
– piston diameter, stroke and function (such
• Compressed air supply:
– supply pressure range in megapascals or
• Filters:
– nominal size in micrometers
• Tubes:
– nominal internal diameter in mm
• Pressure gauges:
– pressure range in megapascals or bar
Pneumatic Control 81
4a Development of single
actuator circuits
Control of SAC
• The piston rod of a single-acting cylinder is to be
extended when pushbutton S1 is pressed and retracted
when the pushbutton is released.
Pneumatic Control 83
Control of DAC
• The piston rod of a double-acting cylinder is to advance
when pushbutton S1 is pressed and retracted when the
pushbutton is released.
Pneumatic circuit diagram Pneumatic circuit diagram with
with 4/2-way valve 5/2-way valve
Pneumatic Control 84
Logic function: AND
Pneumatic Control 85
Logic Function: OR
Pneumatic Control 86
Exercise 1
• Control systems with final control valve
with spring return
Pneumatic Control 87
Exercise 1a
• Title: Sorting device
• Direct actuation of a single-acting
cylinder
• Problem: Draw the pneumatic diagram
Pneumatic Control 88
Exercise 1a: Description
• Using a sorting device, parts are to be
transferred from a conveyor belt. By
pressing the pushbutton switch, the
piston rod of a single-acting cylinder
pushes the part off the conveyor belt.
When the pushbutton is released, the
piston rod returns to the retracted end
position.
Pneumatic Control 89
Exercise 1a: Figure
Pneumatic Control 90
Exercise 1b
• Title: Opening and closing device
• Direct actuation of a double-acting
cylinder
• Problem: Draw the pneumatic diagram
Pneumatic Control 91
Exercise 1b: Description
• Using a special device, the valve in a pipe
line is to be opened and closed.
• The valve is opened by pressing the
pushbutton switch. When the pushbutton
is released the valve is closed.
Pneumatic Control 92
Exercise 1b: Figure
Pneumatic Control 93
Exercise 1c
• Title: Assembly station
• Single-acting cylinder / Double-acting
cylinder
• Direct actuation with AND-function of the
input signals
• Problem: Draw the pneumatic diagram
Pneumatic Control 94
Exercise 1c: Description
• In an assembly station components are to
be put together. By pressing two
pushbutton switches the device is
advanced and the components are
assembled. After releasing the
pushbutton switches, the device is
returned to its start position.
Pneumatic Control 95
Exercise 1c: Figure
Pneumatic Control 96
Exercise 1d
• Title: Cutting device
• Single-acting cylinder / Double-acting
cylinder
• Indirect actuation with AND-function of
the input signals
• Problem: Draw the pneumatic diagram
Pneumatic Control 97
Exercise 1d: Description
• Using a cutting device sheets of paper are
to be cut to size.
• By pressing two pushbutton switches the
cutting blade is advanced and the sheet
of paper is cut. After releasing one
pushbutton switch the cutting blade is
returned to its start position.
Pneumatic Control 98
Exercise 1d: Figure
Pneumatic Control 99
Exercise 2
• Control systems with double solenoid
valve
Pneumatic Control 100
Exercise 2a
• Title: Diverting device
• Single-acting cylinder / Double-acting
cylinder
• Direct actuation from two different
positions
• Problem: Draw the pneumatic diagram
Pneumatic Control 101
Exercise 2a: Description
• Using a diverting device parts are to be moved
from one conveyor track to another conveyor
track.
• By pressing a pushbutton switch the frame of
the diverting device is pushed forward. The
part is moved over and transported onwards in
the opposite direction. By pressing another
pushbutton switch the frame is returned to its
start position.
Pneumatic Control 102
Exercise 2a:Figure
Pneumatic Control 103
4b Development of multiple
actuator circuits
Application example: Feeding device
• The positional sketch of a feeding device is shown in figure below.
The end positions of the two cylinder drives 1A and 2A are
detected by the positive switching inductive proximity switches
1B1 and 2B2.
Pneumatic Control 105
Displacement-step diagram
for the feeding device
• The program-controlled sequence is triggered when the
operator presses the "START" pushbutton. The sequence
comprises the following steps:
– Step 1: The piston rod of cylinder 1A advances.
• The work piece is pushed out of the magazine.
– Step 2: The piston rod of cylinder 2A advances.
• The work piece is fed to the machining station.
– Step 3: The piston rod of cylinder 1A retracts.
– Step 4:The piston rod of cylinder 2A retracts.
Pneumatic Control 106
Displacement-step diagram
for the feeding device
• The "START" button must be pressed again to
trigger another feed operation.
• The program-controlled sequence of motions of
the feeding device is shown in the
displacement-step diagram.
Pneumatic Control 107
Displacement-step diagram
for the feeding device
Pneumatic Control 108
Pneumatic circuit diagram
of the feeding device
• The control system is implemented using double-acting
cylinders and 5/2-way double solenoid valves.
Pneumatic Control 109
Exercise 3: Multiple actuator
• Title: Bench drill
• Draw the pneumatic diagram
• Draw the displacement step diagram
Pneumatic Control 110
Exercise 3: Description
• Workpieces are inserted into the
clamping device by hand. Clamping
cylinder 1A is to extend when the start
button is pressed. When the workpiece is
clamped, it is to be drilled via feed unit
2A and the drill retracted once again. At
the same time, the swarf is to be blown
away by an air jet 3Z. Then, the clamping
cylinder 1A is to release the workpiece.
Pneumatic Control 111
Exercise 3: Figure
Pneumatic Control 112
Exercise 4: Multiple actuator
• Title: Stamping device
• Draw the pneumatic diagram
• Draw the displacement step diagram
Pneumatic Control 113
Exercise 4: Description
• Cylinder 1A is to push parts out of the
gravity feed magazine and clamp them.
Only then can cylinder 2A stamp the part
and retract once again.
• Next, clamping cylinder 1A is to unclamp.
The part is to be ejected by cylinder 3A,
which then returns to the retracted end
position.
Pneumatic Control 114
Exercise 4: Figure
Pneumatic Control 115
5 Design of Pneumatic Circuit
with KV Diagram
Karnaugh Veitch
• The Karnaugh map, also known as a
Veitch diagram (K-map or KV-map for
short), is a tool to facilitate management
of Boolean algebraic expressions.
• The Karnaugh map was invented in 1952
by Edward W. Veitch and developed
further 1953 by Maurice Karnaugh.
Pneumatic Control 117
Additional info needed in KV
Pneumatic Control 118
Main purposes of KV Diagram
• To have a memory in pneumatic circuit.
Pneumatic Control 119
Design of Pneumatic Circuit with KV
B0 A0
A
A1
B
B1 A1
A0 A1 A1 A1 A0
A0
B0 B0 B1 B0 B0
Pneumatic Control 120
