KEMENTERIAN PENGAJIAN TINGGI

MECHANICAL ENGINEERING
DEPARTMENT

PNEUMATIC & HYDRAULICS

Introduction to Pneumatic System

Uma Devi Nadarajah
Norasyidah binti Mohd. Noh
Introduction to Pneumatic System by: ISBN:
Uma Devi Nadarajah
Norasyidah Binti Mohd Noh

Published by:
Politeknik Banting Selangor
Persiaran Ilmu
Jalan Sultan Abdul Samad
42700 Banting, Selangor

https://pbs.mypolycc.edu.my

Copyright © 2021

Editor
M Maniyarasi Munusamy

Cover book by Uma Devi Nadarajah

Pictures by Uma Devi Nadarajah

INTRODUCTION TO PNEUMATIC SYSTEM

Acknowledgement
We are grateful to Politeknik Banting Selangor to give us a wonderful opportunity to write this e-book. We would
like to appreciate everyone who gave us chance to explore the hidden talent inside us to become authors which
might be left deep within us without knowing to this world.

Our heartiest gratitude to e-Learning Unit of PBS, who always share knowledge on e-book writing, encourage us
and being our companion in the discussion of e-book writing.

We would like to express our appreciation to our colleagues, contributors, authors of sources of information who
have directly or indirectly inspired us in completing this e-book.

A very special thanks to our beloved family for being there to support and provide us some space to write this e-
book. Last but not the least, thank you to the God for keeping us positive and hopeful in writing this e-book.

INTRODUCTION TO PNEUMATIC SYSTEM ii

Abstract
This e-book contains subtopic which relates to Chapter 1 of syllabus DJJ40153 Pneumatic & Hydraulics. The
content discussed is related to basic knowledge, application, advantages and disadvantages of the
pneumatic system. Besides that, this e-book also has explained on types of compressor such as
reciprocating piston and rotary compressor. This e-book also covers types of valve and actuator used in
pneumatic system. The advantage of using this book is, it comes with exercise and answers for each
subtopic where students can use this book as a reference for DJJ40153 Pneumatic & Hydraulics. Other than
that, students may opt to answer questions online because each exercise has its link where the questions
were developed using Google form platform to enable the students to know their result immediately after
they answered the questions. For the types of compressor, video link is also given to watch on how the
compressor works. This would give better understanding and learning experience especially when students
use this book for self-study or revision. This interactive e-book would attract the Y generation students who
prefer to use gadget instead of old book style for their teaching and learning activity.

INTRODUCTION TO PNEUMATIC SYSTEM ii

Table of Content
Content Page Number
Acknowledgement i
Abstract ii
Table of contents iii
Introduction to pneumatic system 1
Diagram of structural block and pneumatic system signal flow 5
ISO standard symbol of components in pneumatic 6
Air generation system and air distribution system 8
Types of air compressor 14
Air dehydration 21
Air treatment 28
Valve 32
Directional control valve 33
Non-return valve 38
Flow control valve 42
Pressure control valve 43
Types of actuator 44
Linear actuator 45
Rotary actuator 47
Sizing a cylinder 48
Cushioning 49
References 50
Tutorial questions and answers 51 iii
Introduction to Pneumatic System
1. A pneumatic system is a system that uses compressed air to perform useful work by transmit and
control energy. Compressed air is used as a medium to do work.
2. Pneumatic systems are used in controlling train doors, automatic production lines, mechanical,
clamps, etc.
3. The term Pneumatics comes from the Greek word “pneuma”, which means 'breathe or wind'. It is
basically the use of under pressure gas that helps in performing a certain work in science and
technology.
4. Pneumatics is the science of mechanical properties of elastic fluids.Fluid power system is one that
transmit and control energy through by means of pressurized liquid or gas.
5. In pneumatics, the power is air where the volume of the atmospheric air is reduced by
compression, thus increasing its pressure.

INTRODUCTION TO PNEUMATIC SYSTEM 11

Application of Pneumatic System
1. Pneumatic system that used widely in industrial is commonly powered by compressed air or
compressed inert gases.

Some of the pneumatic applications in industry:

A
Pneumatic A
pneumatic Pneumatic
machine is system in
used to machine is
used in an food
dismantle industry
an automobile
automobile painting
tire

(Images courtesy of Compressed Air & Gas Institute) (Image courtesy of pxfuel.com)

INTRODUCTION TO PNEUMATIC SYSTEM 22

Advantages of pneumatics
1. Availability: Air is available everywhere abundantly and it is free.
2. Transport: Air can flow easily in pipelines regardless of the distance.
3. Storage: Air can be stored and removed easily from the storage.
4. Temperature: Compressed air does not influenced by temperature fluctuations, thus ensures reliable
operation, even under extreme conditions.
5. Cleanliness: Exhaust air without lubrication is clean.
6. Economy: Installation cost for pneumatic system is relatively low cost because of modest component
cost. Furthermore, maintenance cost is also low due to long life without service. The running cost is
also relatively inexpensive.
7. Speed: High working speed is able to achieved because compressed air is a very fast working medium.
8. Overload safe: Pneumatic tools and operating components is unaffected by overloaded. Pneumatic
actuators also free from producing heat except for friction.
9. Explosion proof: Compressed air has a very low risk of explosion or fire, hence it does not require any
expensive protection against explosion.

INTRODUCTION TO PNEUMATIC SYSTEM 33

Disadvantages of pneumatics:

1. Preparation: Compressed air requires good preparation where air has to be filtered in many
stages to remove dirt and condensates.
2. Speed: It is difficult to achieve uniform and constant piston speed because air is compressible.
3. Force requirement: Compressed air is only economical under the normal working pressure of
600 to 700 kPa (6 to 7 bar).
4. Noise level: The exhaust air is loud (noise). However, this problem has now been largely solved
by the development of sound absorption material and silencers.

Portable compressor
(Image courtesy of pixelsquid)

INTRODUCTION TO PNEUMATIC SYSTEM 44

Structural block and pneumatic system signal flow
Air distribution system
Air generation system

(Images courtesy of NPTEL Module 6)

Compressor Air Receiver Dryer Air Service Directional Actuator)

(Tank) unit Valve

INTRODUCTION TO PNEUMATIC SYSTEM 55

ISO standard symbol of components in pneumatic
Symbols for the power supply section Symbols for actuators

(Images courtesy of FESTO)

6
INTRODUCTION TO PNEUMATIC SYSTEM
Symbols for rotary motions Symbols for flow control Symbols for non return valves
valves and derivatives

Symbols for time delay

relay NO

(Images courtesy of FESTO)

INTRODUCTION TO PNEUMATIC SYSTEM 77

 Pneumatic system with elements

Air generation system

Air distribution
system Image courtesy of SMC
basic pneumatic manual

INTRODUCTION TO PNEUMATIC SYSTEM 88

 Air Generation System
1. Compressor is a mechanical device where it produces high
pressurized air by reducing its volume. Temperature of a gas naturally
increases when compression occurs. Air enters to the compressor at Air generation system
atmospheric pressure and compressed at a higher pressure and
delivered to the pneumatic system. During compression, mechanical
energy is transformed into pneumatic energy.

2. Electrical motor is used to supply mechanical power to the

compressor by transforming electrical energy into mechanical energy.

3. Pressure switch is a device that controls the operation of electric

motor. This switch is set to a maximum pressure so that it stops the
motor when pressure in the tank reach its maximum limit and starts
the motor when minimum pressure is detected in the tank.

4. Check valve is used to ensure air from the compressor into the tank is
in one way and prevents the air leaking back when the compressor
stop works.

INTRODUCTION TO PNEUMATIC SYSTEM 99

 Air Generation System
5. Tank or reservoir is a compartment used to store the
compressed air. Besides that, tank also helps to stabilize
the pressurized air. When the compressed air is taken from Air generation system
the system, the tank compensates the pressure
fluctuations. As the pressure in the tank drops to a certain
value, the compressor starts to compensate until the set
maximum value is reached. This cause the compressor to
operate when required only.
6. Pressure Gauge is used to indicate the pressure of the
reservoir.
7. Auto Drain is used to drain out the water deposited in the
tank due to condensation automatically.
8. Safety Valve blows compressed air off when pressure in
the tank rise above the allowed pressure.

INTRODUCTION TO PNEUMATIC SYSTEM 10

10
 Air Generation System
9. Refrigerated Air Dryer helps to cool the compressed air
to a few degrees above freezing point and condenses
most of the air humidity. By doing this, water in the Air generation system
downstream system can be avoided.

10. Line Filter helps to keep the line free from dust, water
and oil. This filter must be able to minimize pressure
drop and remove oil mist.

INTRODUCTION TO PNEUMATIC SYSTEM 11

11
Air Distribution System
1. Air Take-off: Air is received from generation system through air take-
off for distribution. The air take-off is at the top of the main pipe to
ensure condensate remains in the main pipe, water take off from
beneath the pipe will flow into an automatic drain and the condensate
will be removed when it reaches a low point .
2. Auto Drain helps to drain out the remaining water produced from
condensation and must be placed at its lowest point to prevent water
from remaining in the tube.

3. Air Service Unit is a combination of Filter – Regulator –

Lubricator (FRL). Air service unit conditions the
compressed air to ensure the air is clean at optimum
pressure and if required, lubricant is added to extend the
Air distribution life of those pneumatic system components. The type of
system air service unit to be used is depending on application, it
can be FRL or FR type.
Air service unit

INTRODUCTION TO PNEUMATIC SYSTEM 12

12
Air Distribution System
4. Directional Valve pressurizes and exhausts the cylinder ports
alternately to control the direction of movement. This type of
valves controls the direction of air signals by generating,
cancelling or redirecting signals.

5. Actuator is a power component which converts the potential

energy of the compressed air into mechanical energy. Actuator
shown here is a linear cylinder; it can also be a rotary actuator
or an air tool etc.

Air distribution 6. Speed Controllers allows to adjust the speed of the actuator.
system

INTRODUCTION TO PNEUMATIC SYSTEM 13

13
Types of Air Compressors

Reciprocating single
stage piston Diaphragm Screw
compressors compressor compressor

1 3 5

2 4 Click here to watch

Reciprocating double how does an air
stage piston Sliding vane compressor work?
compressor

INTRODUCTION TO PNEUMATIC SYSTEM 14

14
 Types of air compressors

Types of Compressor

Reciprocating Piston
Rotary Compressor Flow Compressor
Compressor

Piston Compressor Diaphragm Radial-flow Axial-flow

( 1 Stage & 2 Stage Piston) Compressor Compressor Compressor

Sliding Vane Rotary Two Axial Screw

Screw Compressor
Compressor Compressor

INTRODUCTION TO PNEUMATIC SYSTEM 15

15
 Reciprocating Air Compressors
1.
2.
One of the main parts that convert
mechanical to pneumatic energy in Reciprocating air compressors
piston compressors is the piston. are positive
The piston performs linear displacement machines, where
reversible motion in the they increase the pressure of the
compressor cylinder. air by reducing its volume.
3.
Major types of reciprocating
compressors include reciprocating
single stage piston compressor, Click here to watch how a
reciprocating double stage piston single stage reciprocating
compressor, and reciprocating compressor works.
diaphragm.

INTRODUCTION TO PNEUMATIC SYSTEM 16

16
 Reciprocating single stage piston compressors
For a single-stage compressor, air from atmosphere is
drawn and compressed to final pressure in one stroke.

The downward movement of the piston increases

the volume to produce a pressure lower than
atmospheric pressure, thereby allowing air to
enter the cylinder through the intake valve.

At the end of the stroke, the piston moves upward,

Working principle of a single stage piston compressor
as the air is compressed, the intake valve closes,
(Image courtesy of Bright Hub Engineering) forcing the exhaust valve to open, and the air is
discharged into the receiving tank.

INTRODUCTION TO PNEUMATIC SYSTEM 17

17
 Reciprocating double stage piston compressor
The air sucked in at atmospheric pressure is
compressed to the final pressure in two stages.

The compressed air enters the secondary cylinder after

passing through the intercooler, and the temperature is
greatly reduced. Compared with the single-stage unit,
the efficiency is improved. The final delivering
temperature can be around 120°C.

Single-stage and two-stage reciprocating compressors

are often used in car and truck repair shops, body
repair shops, service companies, and industrial plants.
Although this type of compressor is usually oil-
Working principle of a double stage piston compressor
lubricated, hospitals and laboratories can purchase oil- (Image courtesy of SMC basic pneumatic manual)
free compressors

INTRODUCTION TO PNEUMATIC SYSTEM 18

18
Sliding vane
1. When the rotor rotates, the blades slide out against the housing.
As the rotor rotates in an eccentric cylinder, air compression
occurs when the volume of the space between the sliding blades
decreases.

2. This type of compressor may or may not be lubricated by oil. Due

to high operating temperature and difficult sealing, oil-free rotary
Working principle of a vane compressor
vane compressors are limited to low-pressure applications. The (Image courtesy of SMC basic pneumatic manual)
oil-lubricated version can obtain higher pressures.

3. Some of the advantages of rotary sliding vane compressors are Click here to watch how a
rotary compressor works
smooth and pulse-free air output, compact size, low noise levels,
and low vibration levels.

INTRODUCTION TO PNEUMATIC SYSTEM 19

19
Screw compressor
1. When the rotor is unmesh at the intake end of the
cylinder, air is drawn into the cavity between the main
rotor blades and the secondary rotor grooves.

Working principle of a screw compressor

(Image courtesy of SMC basic pneumatic
manual)

2. As the rotation continues, the tip of the rotor passes through

the edge of the air inlet, trapping air in the cell formed by
the rotor cavity and the cylinder wall.
Parts in a screw compressor
(Image courtesy of Compressed Air & Gas Institute) Click here to
watch how a
3. As further rotation causes the main rotor blades screw
to roll into the secondary rotor grooves, compressor
compression begins, reducing the volume and works
increasing the unit pressure.

INTRODUCTION TO PNEUMATIC SYSTEM 20

20
Air Dehydration
1 2 3
There are 2 types of Continuous cooler Air Dryer
Air Dehydration: (Aftercoolers) • Absorbance
Continuous cooler a. Air cool – the Drying
(After coolers) cooling process • Adsorption
Air Dryer is done by air Drying
b. Water cool – the • Coolant Drying
cooling process
is done by water

INTRODUCTION TO PNEUMATIC SYSTEM 21

21
 Continuous cooler
1. Air will be hot after final 4. Aftercoolers are heat
compression, thus it will exchangers, being either air
deposit water in the pipeline cooled or water cooled units.
when the air cools down.
5. It is generally equipped with a
The water deposited in the
water separator with
pipeline is in considerable
automatic drainage and
quantities which should be
should be placed close to the
avoided.
compressor.
2. To prevent this, cooler is 3. This process need to be 6. Nowadays, an after-cooler is
used to reduce the done immediately after built into modern
temperature of the compression by forcing the compressors to ease the
compressed air in pneumatic air to aftercooler which process.
systems. This is needed for may help to reduce the
the normal operation of amount of water produced
pneumatic systems. due to condensation.

INTRODUCTION TO PNEUMATIC SYSTEM 22

22
Continuous Cooler
a. Air cooled b. Water cooled

This type of aftercooler uses air to cool down the compressed 1. This type of aftercooler uses water to cool down the hot air after
air. This air cooled aftercooer consists nest of tubes as shown in compression. The arrangement of the air inlet, air outlet, water inlet
figure (a). Hot air enters the aftercooler through inlet and and water outlet are as shown in the figure (b).
passes by the nest of tubes. The air will be cooled down by 2. The flow of water and air should be opposite direction through the
means of cold air produced by fan assembled in the aftercooler. cooler. Temperature of the air discharged should be approximately
10°C above the temperature of the cooling water. The accumulated
condensation is removed through an automatic drain, attached to
aftercooler. Usually, aftercoolers equipped with a safety valve,
pressure gauge, and thermometer pockets for air and water.

a. Principle of an air cooled aftercooler

(Image courtesy of SMC basic pneumatic manual)

Click here to watch

a. Air cooled cooler b. Principle of a water cooled aftercooler
b. Water cooled cooler (Image courtesy of SMC basic pneumatic manual)

INTRODUCTION TO PNEUMATIC SYSTEM 23

23
 Air dryer
(Images courtesy of SMC basic pneumatic manual)

1. Even though, compressed air passed through

an aftercooler which causes condensation
and removes most of the water, filters are
installed to remove additional water, if any.
However, if a system requires further air
treatment, air dryer is preferred.

2. Air dryer ensures most or all of the water in

compressed air is removed before it reaches
critical components or processes.

a b c
3. There are three main types of air dryer
available which operate on an absorption, Absorption Adsorption Coolant drying
adsorption or refrigeration process, will be (deliquescent) (desiccant) (Refrigerant
discussed in this section. Drying Drying drying)

INTRODUCTION TO PNEUMATIC SYSTEM 24

24
Air dryer - absorption
a. Absorption (deliquescent) Drying

1. The compressed air is forced to enter through a desiccant

which has dehydrated chalk or magnesium chloride that
remains in solid form. Lithium chloride or calcium chloride
reacts with moisture to form a solution, which is discharged
from the bottom of the container.

2. During operation, the dew point of the desiccant will

increase with the consumption of salt, but a pressure dew
point of 5°C at 7 bar is possible. Thus, desiccant must be
replenished regularly.

3. The main advantage of this method is the low initial and

operating costs, but the inlet temperature should not exceed
30°C. Since the chemicals used has high corrosive
Principle of the absorption air dryer characteristics, it has to be carefully monitored and filtered
(Image courtesy of SMC basic pneumatic manual) so that small corrosive mists does not enter into the
pneumatic system.

INTRODUCTION TO PNEUMATIC SYSTEM 25

25
 Air dryer – adsorption
b. Adsorption (desiccant) Drying
1. Desiccant air dryer has different working principle where moisture from the air stream and
onto a desiccant material is adsorbed in a reversible process. Dew points produced is low
which means this is air dryer is a good choice when process require extremely dry air.
2. Silica gel or activated alumina in granular form is used as a chemical in this drying process.
This chemical contained in a vertical chamber to absorb moisture from the compressed air
passing through it. The drying agent is regenerated by drying or heating in a regenerating
column when it becomes saturated as shown in the Figure.
3. Wet compressed air enters to the column 1 through a directional control valve and comes out
as dried air to the outlet port.
4. 10 – 20% of the dry air will pass through the orifice O2 and go to the column 2 to reabsorb
moisture from the desiccant to regenerate it. The regenerating air flow then goes to exhaust.
5. To provide continuous dry air, a timer is used to switch periodically the directional control
valve so that the supply air is allowed alternately to one column.
Principle of the heatless 6. The degree of saturation of the desiccant may be monitored by incorporating a colour
adsorption air dryer indicator.
(Image courtesy of SMC basic pneumatic
manual)

INTRODUCTION TO PNEUMATIC SYSTEM 26

26
Air dryer - coolant drying (refrigerant drying)
1. This method cools the compresses air temperature by
removes water and causing condensation. The accumulated
moisture in liquid form is collected by an internal moisture
separator and sends it to a drain.
2. The air generated by refrigerated dryers typically with
pressure dew points between 35 and 40° F, mostly used in
general plant operations.
3. For critical processes which requires extremely dry air, this
method may not be suitable.
4. This dryer is a mechanical unit consisting a refrigeration
circuit, and two heat exchangers.
5. Refer the diagram for the sequence of the process.

Principle of the coolant air dryer

(Image courtesy of SMC basic pneumatic manual)

INTRODUCTION TO PNEUMATIC SYSTEM 27

27
 Air Treatment

1 2 3
Atmospheric air consists of dust Besides that, gummy substances To eliminate these contaminants,
and moisture. Dust usually will be may be formed from fine particles further air treatment is required to
removed by the filter fixed at the of carbonised oil, pipe scale and ensure the compressed air is as
intake of the compressor. other foreign matter, such as worn clean as possible to the point of
Meanwhile, moisture condenses sealing material. This can result in use.
out during the continuous cooling injurious effects on pneumatic
and drying process. However, there equipment by increased seal and
will always be some moisture component wear, seal expansion,
which will be carried over. corrosion and sticking valves.

INTRODUCTION TO PNEUMATIC SYSTEM 28

28
 Air filters
1. To clean the compressed air of all 6. There are three types of air filters
impurities and any condensate it contains.

7. The standard filter is a combined

2. To remove all foreign matter
water separator and filter.

3. To allow dry and clean air flow without 8. A micro-filter is used when contamination by
restriction to regulator and then to the oil vapour is undesirable,
lubricator

4. To condensate and remove water 9. A sub-micro filter will remove

from the air virtually all oil and water and also fine
particles down to 0.01 of a micron…

5. To arrest fine particles and all solid 10. To provide maximum protection for
contaminants from air pneumatic precision measuring devices,
electrostatic spray painting

INTRODUCTION TO PNEUMATIC SYSTEM 29

29
 Function and principle of FRL unit
1. This component is used to 1. Single filter regulator unit
maintain the specific, precise is a combination of air
pressure required by a particular filter and pressure
application, regardless of the rise regulator which provide a
and fall of line and/or receiver compact space saving
pressure as the compressor cuts unit.
in and out.

2. An air pressure regulator is used

to ensure the pressure delivered
to certain components is safe by
reducing the pressure and also
ensure the amount of pressure
received by cylinder is the exact
amount of thrust required.

Pressure Filter-regulator
Regulator (FR) Unit

(Images courtesy of SMC basic pneumatic manual)

INTRODUCTION TO PNEUMATIC SYSTEM 30

30
 Function and principle of FRL unit
1. Pneumatic components usually
consist of internal moving part, thus 1. This unit combines filter,
adding controlled amount of oil regulator and lubricator as
lubricant helps to ensure proper shown in the Figure X. In
lubrication of the components. this unit, filter is the first
component followed by
2. Basically, lubricants are used to regulator and lubricator.
a. To reduce the wear of the
moving parts in components, 2. The arrangement of these
b. Reduce frictional losses components are in such a
c. Protect components and way to prevent 1 foreign
equipment from corrosion. matter from causing a
Filter-regulator- malfunction of the
lubricant Unit (FRL)
3. Lubricator is added in the form of fine regulator. Usually,
mist and it is placed near the lubricator is placed last to
equipment to be lubricated. avoid oil mist or droplets
Lubricator should never be used on - Air Lubricator from deposited in turns or
oil-less compressors. valves in the system.
(Images courtesy of SMC basic pneumatic manual)

INTRODUCTION TO PNEUMATIC SYSTEM 31

31
Valve
Valve is a component that receives internal directions which is in different forms such as manually, mechanically,
electrically and pneumatically to release, stop or discharge back through air flow. The basic function of valves is to
switch direction of the air flow.

Types of pneumatic valves

Directional control Flow control Combination

valve (DCV) valve valve
1 3 5

2 4
Non return valve Pressure control
valve

INTRODUCTION TO PNEUMATIC SYSTEM 32

32
 Directional Control Valve (DCV)
Directional control valve controls the flow of air signals by generating,
cancelling or redirecting signals.

The valve is described by

a. Number of ports or openings (ways): 2-way, 3-way, 4-way, etc.

b. Methods of actuation of the valve:

i. manually actuated
ii. mechanically actuated
iii. pneumatically actuated directional control valve
iv. electrically actuated

c. Methods of return actuation: Spring return, air return and directional

control valves are devices which influence the path taken by an air
stream.

INTRODUCTION TO PNEUMATIC SYSTEM 33

33
Directional Control Valve (DCV)
Description of basic symbols of DCV
c.
Arrowed line indicates the
direction of the flow paths
b. d.
The number of squares Lines drawn at right angles in
(boxes) referring to number the squares are known as
of switching positions the shut off positions
valve has

a. e.
Switching positions of valve The lines on the outside of the
are represented as squares box shows connection ports
(inlet and outlet ports)

INTRODUCTION TO PNEUMATIC SYSTEM 34

34
Methods of actuation of pneumatic directional control valves
roller

3/2 way roller

actuated limit
switch

pilot

3/2 way single

piloted DCV

manually actuated
mechanically actuated 5/2 way double
Pneumatically actuated solenoid DCV

Electrically actuated
(Image courtesy of FESTO) solenoid

INTRODUCTION TO PNEUMATIC SYSTEM 35

35
 How to name a DCV?
no. of ports in a box / No. of boxes– way, method of actuation, method of return DCV

Box 2 (actuation 3/ 2– way NC pushbutton with spring return DCV

state) Box 1 (initial position)
Tips:
2 ❑ Label or port marking only at the initial
position.
❑ The number of port at each box is the same
❑ The normal position (normally open, NO &
1 3
normally closed, NC) need to refer to the port 1
of the initial position. This is only for 3/2 way
Number of squares (boxes) = 2 DCV
Number of ports in one box = 3
method of actuation = push button

method of return = spring

(Images courtesy of Library at AutomationDirect.com)

INTRODUCTION TO PNEUMATIC SYSTEM 36

36
DCV Port Labeling
Direct pneumatic actuation (pilot)
Outlet always use even numbers
Supply always use number 1
Exhaust always use odd numbers (3, 5)

1
Supply

Pilot 14 shows air flows from supply 1 to outlet 4 when DCV is actuated
Pilot 12 shows air flows from supply 1 to outlet 2 when DCV is actuated

Symbols of DCV
(Images courtesy of FESTO)

INTRODUCTION TO PNEUMATIC SYSTEM 37

37
 Non Return Valve (Check Valve)
1. A non-return valve allows air flow freely only in one direction and do not let the air to flow in opposite direction. This
type of valve also known as poppet type valve and is basis for the development of many combined components such
as shuttle valve, quick exhaust valve and one way flow control valve.
2. This is a unidirectional valve where it has two ports: one for the entry of fluid and the other for the discharge.
❑ When air flows from port 1, the check valve allows the air flow by lifting the ball
Check valve against and come out through port 2.

❑ When air flows from port 2, the ball is blocked, thus no air flow is allowed to port 1.
1 2
Working principle of a check valve
2 (Image courtesy of !Original: MionVector: Chris828 at Wikimedia
Flow
blocked Spring Commons)
Spring loaded
check valve Click here to watch
poppet working principle of
Flow check valve
1 allowed

INTRODUCTION TO PNEUMATIC SYSTEM 38

38
Shuttle Valve (OR Valve)
1. Shuttle valve is a three-ported valve which has two inlets and one outlet. When compressed air enters port 12, the
poppet will be pushed to port 14 and it is blocked, thus compressed air flows from port 12 to port 2.

2. This valve is also called as OR valve because port 2 able to produce output, if the compressed air is applied to
either port 12 or 14.

3. A shuttle valve may be used, when the cylinder or valve is to be actuated from two points, which may be remote
from one another.
Truth table for OR valve

Input 12 Input 14 Output 2

Shuttle valve
0 0 0
2 1 0 1
0 1 1
12 14
1 1 1
Click here to watch
Cross sectional view of shuttle valve
working principle of
(Image courtesy of Prabhakar Purushothaman – OR valve
Symbol of shuttle valve Own work, CC BY-SA 4.0, at Wikipedia)

INTRODUCTION TO PNEUMATIC SYSTEM 39

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 Dual Pressure Valve (AND Valve)
1. A dual pressure valve is also a 3-ported valve which has has two inlets and one outlet. A dual pressure valve requires two
pressurised inputs to allow an output. When compressed air enters through port A, the spool will lock and no path for the air
flow to output. Same thing applies when compressed air is supplied through port B. To enable the output X, both port A and
B need to supply with compressed air.

2. This valve is also called as AND valve because port X only able to produce output if both ports A and B applied with
compressed air.

3. Another name for AND function is interlock control. This means control is possible only when two conditions are satisfied.
Truth table for AND valve
Dual pressure X X
A B Input A Input B Output X
valve A B

X 1 1 1
A B 1 0 0

Cross sectional view of dual pressure valve 0 1 0

Symbol of dual (Image courtesy of Prabhakar Purushothaman – 0 0 0
pressure valve Own work, CC BY-SA 4.0, at Wikipedia)

INTRODUCTION TO PNEUMATIC SYSTEM 40

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Quick Exhaust Valve
1. Quick exhaust valve is used to maximize the speed of piston by exhausting the air rapidly to
atmosphere.
2. In many applications especially with single acting cylinders, it is a common practice to increase the
piston speed during retraction of the cylinder to save the cycle time.
3 (exhaust)

❑ When air flows into port 1, port 3 (exhaust) is

blocked, thus air flow to port 2 which is connected
2 (to cylinder)
to actuator Quick exhaust valve

1 2 (to
3 (exhaust)
cylinder)
❑ When air flows coming out from port 2, port 1 1
is blocked, thus air is rapidly released through 3
port 3 (exhaust). 2 (from (exhaust)
cylinder)
1 Symbol of quick exhaust
valve
(Image courtesy of Fastek USA Quick Exhaust Valve XQ series)

INTRODUCTION TO PNEUMATIC SYSTEM 41

41
 Flow Control Valve (FCV) and One Way FCV
Flow Control Valve is used to control the flow rate of the air flow which cause the speed of Flow control valve
actuator becomes slower. (bidirectional)

This flow control valve controls air flow in both directions. The arrow indicates that the valve is
adjustable which means the amount of air flow into the actuator can be adjusted accordingly.

One-way flow control valve controls air flow only in one direction which is through the air
throttle. Generally, this valve used to control speed of actuator and is installed in the
working pressure line, between the final control valve and the cylinder ports.
One way flow
control valve The one-way flow control valve is a combination of a flow control valve and a non return
valve.
1 2
When air flows from Port 1 to 2, it will choose the throttle path to flow since check valve is
blocked. Thus, air flow is controlled.

When air flows from Port 2 to 1, it will choose check valve path because it fully open. Thus
air is free flow

INTRODUCTION TO PNEUMATIC SYSTEM 42

42
Pressure Control Valve
1. Pressure Control valves are used to control pressure in a pneumatic circuit. Example of pressure control valve
are:
❑ Pressure regulator valve which is used to prevent pressure fluctuation in the circuit and control the outlet
pressure below a certain pressure,
❑ Pressure limiting valve or pressure relief valve to ensure the inlet pressure below a certain pressure and
❑ Pressure sequence valve which generates control signal when the valve reaches a certain pressure limit..

pressure sequence valve

(Image courtesy of FESTECH)

INTRODUCTION TO PNEUMATIC SYSTEM 43

43
 Types of actuator
Actuator

Linear actuator Rotary actuator

Double acting
Single acting actuator Air motor Vane motor
actuator

Rack and pinion

INTRODUCTION TO PNEUMATIC SYSTEM 44

44
Linear Actuator – single acting cylinder
Linear actuator can be classified into two groups; air
inlet vent cylinder rod
single acting cylinder and double acting cylinder

1. Single acting cylinder has one air inlet to create a

power stroke in one direction (usually to extend)
and the piston returns to the home position
(retract) by means of spring force.
Single acting cylinder
2. Single acting cylinders are used for applications
such as clamping, marking, ejecting etc.
3. air consumption for single acting cylinder is low
compared with the equivalent size of double
acting cylinder.

Symbol of single acting

cylinder Construction of single acting cylinder
(Images courtesy of NPTEL Module 6)

INTRODUCTION TO PNEUMATIC SYSTEM 45

45
 Linear Actuator – double acting cylinder
air inlet cylinder rod
1. Double acting cylinder has two air inlets to create power strokes
in two directions which is extending and retracting as air
pressure is applied alternately to the air inlets.

2. Double acting cylinders are commonly used in the application

where larger stroke length is required.

3. One of the advantage of the double- acting cylinder is that the

Double acting cylinder
cylinder is able to carry out work in both directions of motion.

4. For the forward stroke, the force transferred by the piston rod is
greater than for the return stroke because of effective piston
surface is reduced on the piston rod side by the cross-sectional
area of the piston rod. However this is only a consideration if the
cylinder is used to “pull” the same load in both directions.
Symbol of double
acting cylinder
Construction of double acting cylinder
(Image courtesy of NPTEL-Module 6)

INTRODUCTION TO PNEUMATIC SYSTEM 46

46
Rotary actuators
b. Rack and pinion
Rotary Actuators
are used for applications required angular motion. This actuator is also referred to as limited rotation
This type of actuator produces high torque output and cylinders, of the single or multiple,
have a limited rotary movement. Standard rotations bidirectional piston are used for turning,
are 90○ , 180 ○ , and 270 ○ . Rotary actuators are positioning, steering, opening and
mainly available in three designs which are ram type, closing, swinging, or any other mechanical function
rack and pinion and air motor. involving restricted rotation.

c. Air motor
a. Ram type Air motors are widely used in
Compressed air enters to air industrial and automotive.
hole which is connected to the Example: Used as a screwdriver,
output shaft. The air openings drilling machine and grinding
is protected from leakage by machine.
using protective rubber or Air motor produces a continuous
elastomeric coating. output torque to move the shaft.

INTRODUCTION TO PNEUMATIC SYSTEM 47

47
 Sizing a Cylinder
1. Linear cylinders have the following standard diameters as recommended in ISO:

8, 10, 12, 16, 20, 25, 32, 40, 50, 63, 80, 100, 125, 140, 160, 200, 250, 320 mm

2. The force developed by a cylinder is a function of the piston diameter, the operating air pressure and the frictional resistance.
This, theoretical force, is calculated using the formulae:

Force (N) = Cross section area of Piston area (m2) X air pressure (N/m2)

Extending stroke for a double acting cylinder: X efficiency where, D = piston diameter,
Pg = Working (gauge) pressure

Retracting stroke for a double acting cylinder: X efficiency where, d = piston rod diameter

For a single acting cylinder, extending stroke: X efficiency where, Fs= spring force at the end of stroke

INTRODUCTION TO PNEUMATIC SYSTEM 48

48
Cushioning
1. High speed movement created by pneumatic cylinders result in
considerable development of shock forces on the end of the stroke
when the piston touching the cylinder cover or lid rod at the end of
each stroke. This impact force can damage the piston or piston rod. To Is used for large cylinders
avoid this, cushioning is required for cylinders.
larger cylinders, the impact
Types of cushioning effect can be absorbed by an air
cushion that decelerates the
piston over the last portion of
the stroke.
Is used for small cylinders Rubber buffer Air cushions
often have fixed cushioning i.e.
rubber buffers, to absorb the
shock and prevent internal
damage to the cylinder.

INTRODUCTION TO PNEUMATIC SYSTEM 49

49
 References
1. SMC Pneumatics Inc. (1997). Basic pneumatics (Rev. 0100 ed.) [E-book].
2. FESTECH Factory Automation Expert Group. (2007). Practical pneumatics. FESTECH.
3. IAT Curriculum Unit, Institute of Applied Technology. (2011). Basic Hydraulics and Pneumatics Module 1: Introduction to Pneumatics. Silo. Tips.
https://silo.tips/download/basic-hydraulics-and-pneumatics#modals
4. NPTEL – Mechanical – Mechatronics and Manufacturing Automation. Lecture 1 pneumatic system, lecture 2 compressors, lecture 3 air treatment
and pressure regulation. In Joint initiative of IITs and IISc – Funded by MHRD (Ed.), Module 6: Pneumatic Systems (pp. 1–26).
5. Bright Hub Inc. (2010, February 11). Air compressor operation: Description of two stage and theory. Bright Hub Engineering.
https://www.brighthubengineering.com/hvac/63715-operation-of-an-air-compressor/https://www.brighthubengineering.com/hvac/63715-
operation-of-an-air-compressor
6. Tyler Currie. (2015, March 5). After-cooler for air-compressor– that ain’t a dryer! Van Air Systems. https://www.vanairsystems.com/after-cooler-for-
air-compressor-that-aint-a-dryer/

Videos:
1. How does an air compressor work video:
https://www.youtube.com/watch?v=bJluUxA7aaY&list=PLpA864g8WSUuIqmpbDdbyDeqg0fT4Hs_8&index=2
2. Single stage reciprocating video: https://www.youtube.com/watch?v=BeFEmIzZvEA
3. Rotary compressor video: https://www.youtube.com/watch?v=b93GSe-xgqI
4. Screw compressor video: https://youtu.be/YMFe7saE-_E?list=PLpA864g8WSUuIqmpbDdbyDeqg0fT4Hs_8
5. Air cooled cooler video: https://www.youtube.com/watch?v=Y1ibPUcj-Yg
6. Water cooled video: https://www.youtube.com/watch?v=ckXyj_wpyVc
7. Check valve video: https://www.youtube.com/watch?v=lwI9D_DRg_g&t=20s
8. Shuttle valve video: https://www.youtube.com/watch?app=desktop&v=tVghySXf8TU

INTRODUCTION TO PNEUMATIC SYSTEM 50

50
 Introduction to Pneumatic System

Chapter 1 – Introduction to Pneumatic System

Answer all the questions (Click here for online exercise)

1. What is pneumatic system?

A.a system that uses compressed air to transmit and control energy to perform useful work
B.a system that uses compressed air to control energy to perform useful work
C.a system that uses air to transmit and control energy to perform useful work

2. Which is the correct statement about the pressure developed in the air compressor?

A. The pressure generated is lower than atmosphere pressure.

B. The pressure generated is depending on the temperature during the compression
process
C. The air from the atmosphere is reduced in volume by compression, thus increasing its
pressure.

3. Pneumatic sytem is using ____________________as a working medium.

A. Oil
B. Compressed air
C. Water

4. What is X in the given figure?

Structural block of
pneumatic system

A. Air conditioning
B. Dryer
C. Air regulator

5. Pneumatic system is preferred in food industry because ________

A. the cost is low
B. it is using air as a medium which is available everywhere
C. it is using unlubricated air which is clean
 Chapter 1 – Introduction to Pneumatic System

6. Picture below shows the ISO standard symbols for .

A. Flow control valve

B. Directional control valve
C. Pressure control valve

7. Why compressed air requires good preparation?

A. So that pneumatic system is clean
B. To protect the operator from dirt and dust
C. To maximize performance and extend the life of the components doing the work
in a pneumatic system

8. Name the component that is used to transform the potential energy of

the compressed air into mechanical work.
Answer: _______________________________________

9. Symbol shown in figure below is a combination of ______________

A. Air filter, regulator

B. Air filter, regulator, check valve
C. Regulator, lubricator
D. Air filter, regulator, lubricator

10. Which of the following components list belongs to air generation system?
A.Actuator, check valve, air service unit, compressor
B.Tank, actuator, pressure switch, electric motor
C.Pressure switch, electric motor, compressor, check valve
D.Directional control valve, line filter, compressor, auto drain
 Introduction to Pneumatic System

Chapter 1 – Introduction to Pneumatic System – Air dehydration & Treatment

Answer all the questions (Click here for online exercise)

1. There are TWO (2) types of air dryer.

A. True B. False

2. Which process is the following statement refers to?

"After final compression the air will be hot, when it cools it will deposit water in
considerable quantities in the airline (pipe system) system which should be avoided.”

A. Water cool B. Aftercoolers

C. Absorption drying D. Adsorption drying

3. Diagram below shows

A. Desiccant air dryers B. Refrigerant drying

C. Main line filter D. Deliquescent air dryers

 Introduction to Pneumatic System

4. Which of the following statement describes best about the diagram shown below?

A. air flows from the compressor to an aftercooler that lowers the temperature (within
10-15°C of the cooling medium), causes condensation and removes the majority
of water.

B. a steel shell housing tubes with water circulating on one side and air on the other,
usually arranged so that the flow is in opposite directions through the cooler.

C. The cold dry air return pipe passes through air heat exchanger and gains heat
from the incoming high temperature air.

5. What is the purpose of air treatment in air generation system?

A. To remove heat after compression, the air should be further cooled as

near as possible to the point of use

B. To remove remaining moisture, contaminants such as fine particles of

carbonised oil, pipe scale and other foreign matter, the air should be further
cleaned as near as possible to the point of use

C. To remove moisture from the air after air is cooled down by air dryers.
 Introduction to Pneumatic System

Chapter 1 – Introduction to Pneumatic System - Valves

Answer all the questions

1. Which of the following is the function of directional control valve, DCV?

A. control flow of the air B. control the direction of the air

C. control the speed of the air D. control the pressure of the air

2. Which of the following is NOT the actuation method of

a pneumatic DCV?

A. mechanically B. manually
C. hydraulically D. combination

3. How many groups of pneumatic valve can be divided?

A. 4 B. 5
C. 3 D. 6

4. Which of the following does not belongs to non return valve?

A. shuttle valve B. dual pressure valve

C. quick exhaust valve D. sequence valve

5. Valves shown in figure can be categorized as

valve

A. non return valve B. directional control valve

C. flow control valve D. pressure control valve
 Introduction to Pneumatic System

6.
Name the component shown in the figure.

A. one way flow control valve B. flow control valve

C. shuttle valve D. AND valve

7.
What is the name of the component shown in the figure?

A. 3/2 way single button DCV B. 3/2 way NC pushbutton DCV with
spring return
C. 3/2 way NO pushbutton DCV with
D. 3/2 way double pilot with spring
spring return
return DCV

8.
What is the name of this component?

A. 5/2 way double pilot B. 4/2 way double pilot DCV with
spring return
C. 5/2 way single pilot DCV with
D. 4/2 way single pilot DCV with
spring return
spring return

9.

What is the name of the component shown in the figure?

A. 5/3 way hand lever valve with B. 4/3 way hand lever valve with
closed mid position open mid position
C. 4/3 way hand lever valve with D. 5/3 way hand lever valve with
closed mid position closed mid position

10. What is the name of the component shown in the

figure?

A. dual pressure valve B. shuttle valve

C. check valve D. quick exhaust valve
 Introduction to Pneumatic System

11. What is the component in the figure?

A. non return valve B. spring valve

C. check valve D. filter

12.

What is the name of the component in the

figure?

A. Drain B. Filter
C. Cooler D. Heat exchanger

13.

What is the name of this component?

A. AND Valve B. shuttle valve

C. quick exhaust valve D. NOT valve

14. How many control position does this valve has?

A. 5 B. 2
C. 3 D. 4

15. Which operating method of a directional control valve is

shown?

A. general B. push button

C. pedal D. detent lever

16. Which actuation method of a directional control valve

is shown?

A. roller B. spring centering

C. return spring D. idle return roller
 Introduction to Pneumatic System

17.
What is the function of this component?

A. control flow of air in one direction B. control direction of the air in one
direction
C. control flow of air in both direction
D. allow flow of air in one direction only

18. How many port does this valve has?

A. 5 B. 2
C. 3 D. 4

19. What is the function of this valve?

A. allow flow of air to the outlet when there B. allow flow of air to the outlet when
are pressure at both inlets there is pressure at any of the inlet
C. exhaust the cylinder air quickly to D. unidirectional valve and permit the
atmosphere. free flow in one direction only

20. Which of the following statement is not correct about this

component?

A. this valve is a combination of a B. When air flows from Port 1 to 2, it will

flow control valve and a non choose the throttle path to flow since check
return valve valve is blocked. Thus, air flow is controlled.
C. controls air flow in both D. When air flows from Port 2 to 1, it will
direction which is through the air choose check valve path because it fully open.
throttle Thus air is free flow
 Introduction to Pneumatic System

Chapter 1 – Introduction to Pneumatic System – Actuators

Answer all the questions (Click here for online exercise)

1. The pneumatic actuator can be categorized into two groups. Name the two groups.
Answer: ____________________________________________

2. Which cylinder is the following statement referring to?

'The cylinder uses the pressure imparted by compressed air to create a driving force in

one direction (usually out), and a spring or by external force from the load or spring to
return to the "home" position.'

Answer: ____________________________________________

3. Name the cylinder shown and label the parts in the Figure 1

Figure 1

Answer: ____________________________________________

4. Which of the following statements describes best about double acting cylinder?
A. thrust is developed in extending direction only as air pressure is applied
alternately to opposite sides of a piston.
B. thrust available on the extending stroke is reduced due to the smaller effective
piston area, but is only a consideration if the cylinder is to “pull” the same load
in both directions
C. thrust available on the retracting stroke is reduced due to the smaller effective
piston area, but is only a consideration if the cylinder is to “pull” the same load
in both directions.

5. Name TWO (2) types of cushions in pneumatic cylinder.

Answer: ____________________________________________
Chapter 1: Introduction to Pneumatic System

Answer.

1. B - A system that uses compressed air to control energy to perform useful work.
2. C - The air from the atmosphere is reduce in volume by compression, thus increasing its
pressure.
3. B - Compressed air.
4. B - Dryer
5. C - It is using unlubricated air which is clean.
6. A - Flow control valve.
7. C - To maximize performance and extend the life of the components doing the work in a
pneumatic system
8. Actuator / cylinder
9. A – Air filter, regulator.
10. C - Pressure switch, electric motor, compressor, check valve

Chapter 1: Introduction to Pneumatic System – Air dehydration & Treatment

Answer.

1. B - False
2. B - Aftercoolers.
3. A – Desiccant air dryers.
4. B - A steel shell housing tubes with water circulating on one side and air on the other, usually
arranged so that the flow is in opposite directions through the cooler.
5. B - To remove remaining moisture, contaminants such as fine particles of carbonised oil,
pipe scale and other foreign matter, the air should be further cleaned as near as possible to
the point of use

Chapter 1: Introduction to Pneumatic System – Valves

Answer.

1. B - Control the direction of the air.

2. C – hydraulically.
3. B – 5.
4. D – sequence valve.
5. D – pressure control valve.
6. A – one way flow control valve.
7. B – 3/2 way NC pushbutton DCV with spring return.
8. D – 4/2 way single pilot DCV with spring return.
9. C – 4/3 way hand lever valve with closed mid position.
10. D – quick exhaust valve.
11. C – check valve.
12. B – filter.
 13. B - shuttle valve.
14. C– 3.
15. C – pedal.
16. D – idle return roller.
17. C – control flow of air in both directions.
18. A – 5.
19. A – allow flow of air to the outlet when there is pressure at both inlets.
20. C – controls air flow in both direction which is through the air throttle.

Chapter 1: Introduction to Pneumatic System – Actuators.

Answer.

1. Linear, rotary
2. Single acting cylinder.
3. Single acting cylinder
A – pressure port.
B – vent.
C – rod.
D – piston seal.
E – spring.
4. C – thrust available on the retracting stroke is reduce due to smaller effective piston area,
but is only a consideration if the cylinder is to ‘pull’ the same load in both directions.
5. Air cushions, rubber buffer.
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