2.1.
1 The Basic of Pneumatic System
Pneumatic cylinders, rotary actuators and air motors provide the force and movement of most
pneumatic control systems to hold, move, form and process material. To operate and control
these actuators, other pneumatic components are required i.e. air service units to prepare the
compressed air and valves to control the pressure, flow and direction of movement of the
actuators.
A basic pneumatic system, shown in Fig 2.2, consists of two main sections:
Figure 2.2: Basic Pneumatic System
The Air Production and Distribution System
(1) Compressor: Air taken in at atmospheric pressure is compressed and delivered at
higher pressure to the pneumatic system. It thus transforms mechanical energy into
pneumatic energy.
(2) Electric Motor: Transforms electrical energy into mechanical energy
(3) Pressure Switch: Controls the electric motor by sensing the pressure in the tank.
(4) Check valve: Lets the compressed air from the compressor into the tank. It is set to a
maximum pressure at which it stops the motor and a minimum pressure at which it
restarts it.
(5) Tank: Stores the compressed air.
(6) Pressure Gauge: Indicates the Tank Pressure.
(7) Auto Drain: Drains all the water condensing in the tank without supervision.
(8) Safety Valve: Blows compressed air off if the pressure in the tank should rise above
the allowed pressure.
(9) Refrigerated Air Dryer: Cools the compressed air to a few degrees above freezing
point and condenses most of the air humidity.
(10) Line Filter: It helps to keep the line free from dust, water and oil.
The Air Consuming System
(1) Air Take Off.
(2) Auto Drain.
(3) Air Service Unit.
(4) Directional Valve: Alternatively pressurizes and exhaust the cylinder connections to
control the direction of movement.
(5) Actuator.
(6) Speed Controllers: Allows easy speed adjustment of the actuator movement.
2.1.2 Components and Symbol of Pneumatic System
The primary levels in a pneumatic system are:
Energy supply/Air generation and distribution.
Input elements (sensors).
Processing elements (processors).
Actuating devices (actuators)
The elements in the system are represented by symbols which indicate the function of the
element. The symbols can be combined to represent a solution for a particular control task
using the circuit diagram. The circuit is drawn with the same structure as the signal flow
diagram above. At the actuator level the addition of the control element completes the
structure. The control element controls the action of the actuator after receiving signals sent
by the processor elements.
Figure 2.3: Pneumatic elements
The directional control valve (DCV) may have a sensing, a processing or an actuating
control function. It the DCV is used to control a cylinder motion, then it is a control element
for the actuator group. If it is used in the function of processing signals, then it is defined
as a processor element. If it is used to sense motions, then it is defined as a sensor. The
distinguishing feature between each of these roles is normally the method of operating the
valve and where the valve is situated in the circuit diagram.
The development of pneumatic systems is assisted by a uniform approach to the
representation of the elements and the circuits. The symbols used for the individual
elements must display the following characteristics:
Function
Actuation and return actuation methods
Number of connections (all labeled for identification)
Number of switching positions
General operating principle
Simplified representation of the flow path
A symbol does not represent the following characteristics:
Size or dimensions of the component
Particular manufacturer, methods of construction or costs
Orientation of the ports
Any physical details of the element
Any unions or connections other than junctions
The symbols used in pneumatics are detailed in the standard DIN ISO 1219, "Circuit
symbols for fluidic equipment and systems.
(a) Air generation and distribution
The air supply for a particular pneumatic application should be sufficient and of adequate
quality.
Air is compressed to approximately 1/7th of its volume by the air compressor and delivered
to an air distribution system in the factory. To ensure the quality of the air is acceptable,
air service equipment is utilized to prepare the air before being applied to the control
system.
Malfunctions can be considerably reduced in the system if the compressed air Is Correctly
prepared. A number of aspects must be considered in the preparation of the service air:
Quantity of air required to meet the demands of the system
Type of compressor to be used to produce the quantity required
Storage required
Requirements for air cleanliness
Acceptable humidity levels to reduce corrosion and sticky operation
Lubrication requirements, if necessary
