MODULE 4: PNEUMATIC POWER SYSTEMS

Introduction to Pneumatic Systems: Pneumatic power system, advantages, limitations,

applications, choice of working medium. Characteristics of compressed air and air
compressors. Structure of pneumatic control system, fluid conditioners – dryers and FRL
unit.
Pneumatic Actuators: Linear cylinder – types of cylinders, working, end position
cushioning, seals, mounting arrangements and applications. Rotary cylinders – types,
construction and application, symbols.
Pneumatic Control Valves: DCV such as poppet, spool, suspended seat type slide valve,
pressure control valves, flow control valves, types and construction, use of memory valve,
Quick exhaust valve, time delay valve, shuttle valve, twin pressure valve, symbols.

INTRODUCTION

The working concept of a pneumatic system is similar to that of a hydraulic power system.
Pneumatic systems use pressurised gas, mostly air, to transmit motion and power.

CHOICE OF WORKING MEDIUM:

The choice of the working medium depends basically on the type of application. Some of the
general, broad rules followed in the selection of a working medium are listed below:

i) When a system needs high speed, medium pressure and less accuracy a pneumatic
system is good. If the system requires high pressure and high accuracy, a fluid system
with oil is good.
ii) When the power requirements are very high, like in a power press, oil hydraulics is
the option.
iii) Location of the system also plays a role in the selection of a working medium. For
location with severe temperature variations, oil hydraulic system will do better, where
an air system may lead to severe condensation problems.
iv) Another issue related to the selection of working medium is that of fire/electric
hazards. Air being non-explosion in nature, it is preferred where fire/electric hazards
are expected. Oil systems are more prone to fire and electrical hazards and are not
recommended in such areas.

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 ADVANTAGES OF COMPRESSED AIR (PNEUMATIC SYSTEMS):

i) Air is available in abundance at all locations.

ii) Air can be transported from the source to the point of utilisation very
conveniently through piping layout, and there are no limitations on the distance.
iii) Compressed air can be stored conveniently in a reservoir and used whenever required.
iv) Compressed air is free from explosion and electrical hazard problems.
v) Air is clean and has no leakage/messy problems like hydraulic fluids.
vi) Generally, temperature variations do not affect the performance of air systems,
as long as good air treatment systems (filter, regulator, lubricator) are
maintained.
vii) Most components of air system are simple and compact in design.

DISADVANTAGES OF COMPRESSED AIR (PNEUMATIC SYSTEMS):

i) Power: Air as a working medium is not useful for high power and high
precision applications, since it is compressible in nature.
ii) Lubrication: Air is not a good lubricating medium unlike the hydraulic fluid.
iii) Heat Dissipation: Air due to its low conductivity, cannot dissipate heat as much as
a hydraulic fluid.
iv) Sealing: Air cannot seal the fine gaps between the moving parts unlike the
hydraulic fluid.
v) Noise & Condensation: Air as a working medium is always noisy, and is prone
to severe condensation problems with temperature variations.
Applications of Pneumatic System:
Pneumatic systems have an infinite number of applications in today’s modern era. Some of
the main applications of pneumatic systems are.
 Automatic production lines.
 Doors of metro trains.
 Medical equipment.
 Car washing.
 Pneumatic brakes.

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STRUCTURE OF A PNEUMATIC SYSTEM:

In this system, an electric motor drives an air compressor. The atmospheric air is sucked by
the compressor through the filter. The purpose of the filter is to separate air from suspended
and other dust particles. The compressor line is provided with a pressure switch, to protect
the system pressure rising beyond the safe level by stopping the electric motor supply. Since
the compression process increases the temperature of the compressed air, the air is passed
through an air cooler to cool the air to environmental condition. This air is then stored in a
storage reservoir, usually a large cylindrical steel container. From the reservoir, the
compressed air is supplied to various systems for use.

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PRODUCTION OF COMPRESSED AIR:

Compressed air is produced using compressors and stored in a reservoir. Before the
atmospheric air is drawn into the compressor, it passes through a filter to remove the
atmospheric dirt and other particles so that only clean air enters the compressor. In the
compressor unit run by an electric motor, the volume of the drawn air is reduced so that its
pressure increases. This increase in pressure is associated with an increase in temperature of
the compressed air. Hence an air cooler is use to cool the air before it is sent to reservoir.

Since the atmospheric air is humid, after compression and cooling, it condenses into small
droplets. This moisture causes corrosion and operational problems. A separator is used to
remove water particles from the compressed air. This air after cooling and separation (i.e.,
primary treatment) is sent to the reservoir. Once the reservoir is filled with compressed air
and pressure reaches a safe limit value, it is sensed by a pressure switch, which in turn

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switches the compressor-motor off. With usage the pressure drops down, which is again
sensed by the pressure switch, and in turn switches the motor on.

In pneumatic systems, unlike the hydraulic systems, the compressed air has no lubricating
ability. Thus, the stored air before being sent to do some work is mixed with an oil mist. This
not only provides lubrication to mating parts, but also reduces the corrosive problems. In
practice, the compressed air after mixing with oil mist is further subjected to filtering and
moisture separation again to make the air further clean. This treated air is then sent to the
control valves and to the actuators to do the work.

PERFECT GAS LAWS:

The laws that determine the interactions of pressure, volume and temperature of a gas are
called the “perfect gas laws”. Even though perfect gases do not exist, air behaves very closely
to that predicted by Boyle’s law, Charle’s law, Gay-Lussac’s law and general gas law for the
pressure and temperature ranges experienced by pneumatic systems.

Boyle’s Law:

It states that if the temperature of a given amount of gas is held constant, the volume of the
gas will change inversely with the absolute pressure of the gas.

V1

P2 V2 P1

Charles’ Law:

It states that if the pressure on a given amount of gas is held constant, the volume of the gas
will change in direct proportion to the absolute temperature.

V1 T
 1
V2 T2

Gay-Lussac’s Law:

It states that if the volume of a given gas is held constant, the pressure exerted by the gas is
directly proportional to its absolute temperature.

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 P1 T
 1
P2 T2

General Gas Law:

It contains all three gas parameters (pressure, temperature and volume), since none are held
constant during a process from state 1 to state 2. It is defined as

P1V1 P V
 2 2
T1 T2

COMPRESSORS:

Compressors are the source of pneumatic power. These can be classified into two categories:
positive displacement and non-positive displacement type. Piston-type and screw-type are
positive displacement type and most widely used compressors for small and medium power
pneumatic applications, while centrifugal and axial type are non-positive type.

Piston-type Compressor:

This is the most widely used type of compressor in the industry for production of compressed
air. It has a piston-cylinder arrangement, with inlet and outlet valves. The piston is driven by
a crank and connecting rod, which converts the rotary motion of the motor into reciprocating
motion of the piston. In operation, in the first cycle (the half revolution of the shaft) the inlet
valve opens, the atmospheric air is drawn-in by the piston as it moves down. In the next cycle

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(the second half revolution of the crank shaft), the inlet valve gets closed, the outlet valve
opens and the air is compressed as the piston moves up in the cylinder. The air compression
process is accompanied with an increase in temperature. The air is cooled by providing fins
around the cylinder.

Screw-type Compressor:

A screw compressor is a rotary type compressor, which is simple in construction and

operation. It has two intermeshing rotating screws with close working tolerances. These
screws are housed in a casing with inlet and outlet ports. In operation as the screw rotate, the
atmospheric air is drawn-in, trapped between the rotating/meshing screws, which is carried
along the screws up to the outlet port. Since, the screws mesh continuously, the air
compression and delivery occurs continuously without any pulsation. For wear free and
reduced noise operation some kind of lubrication forming a thin oil film is used. The oil
injected to the chamber lubricates the screw surfaces and forms a seal so that air is
compressed efficiently, as the screws mesh continuously.

FLUID CONDITIONERS:

The compressed air gets contaminated due to atmospheric dust, lubricant, moisture and so on.
If this air is used directly it may block the control valves, damage the components and/or
cause corrosion related problems. Hence, before it is actually used for pneumatic application
the air is prepared by removing various contaminants. Fluid conditioners include filters,
regulators, lubricators and air dryers.

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Air Filters:

Filters are provided both at the compressor inlets and in the pneumatic lines before the
valves/actuators. Intake filters are mostly paper type elements, which prevent the entry of
atmospheric contaminants into the compressor and minimise damage to the compressor
components. The other filter, termed the air-line filter is used in the pneumatic lines to
remove contaminants, mainly fine dirt and moisture. The air-line filters protect the pneumatic
control valves and other devices.

Air Dryer:

The air filter can only remove condensed water particles from air. The vapour passes through
the air-filter and causes problems as it condenses at other components. In a compressed air,
the relative humidity (RH) and dew point are higher. Both the RH and the dew point are
dependent on the temperature and pressure. Whenever the temperature drops and/or the
pressure increases the water condenses. This problem can be reduced by keeping the
humidity of air below 100%, for which air-dryers are used.

Lubricators:

Unlike the hydraulic systems, the dry air in the pneumatic systems cannot provide a
lubrication effect in the devices. Generally, oil in the form of fine mist is added to the clean
dry air during the secondary treatment. For this air lubricators are used.

Air Pressure Regulator:

In pneumatic systems the flow velocities are quite high, which may lead to considerable
pressure drops between the air receiver and the loading point. Hence, it is a common practice
to maintain a higher pressure in the reservoir than that is required at the actuator. The
required pressure at the loading point is then achieved using pressure regulation locally using
air pressure regulators.

Air pressure regulators are similar to pressure reducing valves used in hydraulic systems. Air
pressure regulators in pneumatic systems are used to adjust the supply pressure to a required
level for a given load irrespective of the air flow, i.e., to maintain a constant pressure at the
load: that means, if the air flow is higher, it senses the pressure and reduces the flow rate to

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the required level to maintain the pressure. Similarly, if the supply pressure drops, the
regulator increases the flow rate so as to increase the pressure to the required level.

PNEUMATIC ACTUATORS

Pneumatic actuators convert the air pressure into linear or rotary motion depending upon their
design. Similar to hydraulic actuators, pneumatic cylinders are also use for gripping/moving
of objects in various industrial applications. Pneumatic actuators which are designed to
produce linear motion are termed linear air cylinders. Actuators which are designed to
produce rotary motion are termed rotary cylinders or more popularly air motors.

Linear Cylinders:

Classification of Air Cylinders:

Linear pneumatic cylinders, popularly known as air cylinders are used for the generation of
straight rectilinear motion. Thus, they are useful to move an object or apply a force on an
object in a straight line.

Pneumatic cylinders are briefly classified as follows:

1) Single acting cylinder: It is a cylinder in which air pressure is applied on to the piston
side only and extension takes place by the air pressure in one direction. The return stroke
is mostly by gravity.
2) Spring Return Cylinder: It is a single acting cylinder in which movement in one
direction is under air pressure, while the return stroke is accomplished by a spring.
3) Ram Cylinder: in this the cylinder rod itself forms the movable element termed as ram.
It is usually single acting and return stroke is either under gravity or assisted by return
cylinders.

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4) Double acting cylinder: it is a cylinder in which the ait pressure is applied alternately on
either side, so that
5) Double rod or through-rod cylinder: In a double-rod or through-rod cylinder, the
piston-rod extends/retracts on either end of the cylinder.
6) Rod-less cylinder: In this, there is no rod connected to the piston. Usually, the piston is a
magnetic type, while an external follower (magnetic) follows the piston due to magnetic
coupling.
7) Diaphragm Cylinder: For short stroke lengths, small cylinders with a rubber or metal
diaphragm is used instead of a piston. The main advantage of such cylinders is that there
is no leakage between the inlet and outlet chambers; and there is no frictional loss.

SEALS:

Seals are used to avoid leakage and for smooth, wear free operation. Depending upon the
type of construction, seals are used at different locations in a linear cylinder.

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1) Piston Seals: Piston seals or piston rings are used between the piston and the barrel.
These rings can be either metallic or non-metallic. Steel rings coated with zinc phosphate
or manganese phosphate give a good life and operate smoothly. Non-metallic rings made
of PTFE (polyterafloroethylene), widely known as Teflon is chemically stable and tough.
Because of its very low coefficient of friction (0.04), it is ideal in pneumatic cylinders,
and can perform well without lubrication also.
2) Piston Cups: In some constructions, the piston is provided with piston cup seals.
Compared to piston with rings, cup seals are much simpler in design and easy to
assemble. They have an L-section, held on either side of a backing plate. For a single
acting cylinder one cup is used on the pressure side, while for a double acting cylinder
two cups, one on either side are used. The cups are held between the backing plate and
retainer clamp. Leather or some synthetic materials are used for sealing cups.
3) Rod Seals: Rods are provided with three varieties of seals: (i) a dynamic seal (synthetic
material) to prevent leakage of air; (ii) a rod bearing (Teflon) to support the rod in the end
cap: and (iii) a rod wiper (synthetic) to prevent entry of atmospheric contaminants. In
very dusty environments, rubber bellows are also used to protect the cylinder from the
dust and other external particles.
4) End Cap Seal: Depending upon the design, either O-rings or die-cut gaskets are used to
seal the end cap and the barrel. Synthetic rubbers and leather are commonly used for this
purpose.

END POSITION CUSHIONING:

Normal single-acting and double-acting cylinders, while moving heavy loads, may undergo
sudden impacts at the end of strokes. This sudden deceleration may cause damage to the load,

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or cylinder or to the pneumatic system itself. To avoid this problem, end-position cushioning
is provided in cylinders.

In this, the piston end is provided with a plunger (or a cushioning piston), the air inlet port is
such that it matches with the cushioning plunger size. At the end of stroke, the cushioning
piston mates with the inlet port and blocks the direct flow path for the air.

The exhaust air now passes through a small, adjustable restricted opening. Since air cannot
pass out easily, the restricted flow through small openings provides a cushioning effect to the
decelerating cylinder. Thus, in the last part of the stroke, the piston speed gets reduced
gradually, which otherwise would have been stopped instantly. The area of the restricted flow
path, hence the cushioning effect can be adjusted with an adjustable screw.

For the onward stroke, since the main entry is blocked by the cushioning plunger, a by-pass
check valve is provided. The air passes freely through the check valve against a bias spring
pressure. During cushioning action (in the retraction mode), the check valve is non-
operational, hence no air can escape through it.

RODLESS CYLIDERS:

As the name suggests, these are cylinders without any rod extending from them. A rodless
cylinder has a barrel with rodless piston. In some applications, where there is not enough
space is available for the rod extension, or where the stroke length required is too high, then
rodless cylinders are quite useful.

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In this, the piston is rodless, and is freely movable within the cylinder barrel. The piston has
no positive/rigid connection to the external member for actuation. The piston has a set of
annular magnets fitted around it. The external member/actuator is a magnetic follower, and it
is linked to the piston due to magnetic coupling between them. As the piston moves under
fluid pressure, the external sliding member moves in synchronisation with it. The load to be
moved is mounted on a carriage, which in turn is connected to the magnetic slide. Hence,
when the slide moves the carriage along with the load moves in the direction of movement of
the piston.

Advantages:

1) The construction of the cylinder is simple as the barrel is sealed from both ends.
2) Such a cylinder has no rod extending from the cylinder and convenient for
space contained applications.
3) The cylinder can be used for extreme stroke lengths
4) Flatbed carriages can be used for carrying the loads.
5) The construction can be made compact by concealing the cylinder below the carriage.

PNEUMATIC CONTROL VALVES

Classification of Pneumatic valves:

1) Direction Control Valves

a) Poppet Valves
b) Spool (slide) Valves
2) Flow control Valves
3) Pressure control Valves

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4) Non-return Valves
a) Check Valve
b) Shuttle Valve
c) Quick Exhaust Valve

Poppet Valves:

In poppet valves (also termed seat valves) are used to control the air flow. In a simple poppet
valve, the poppet is operated manually. It has a cylindrical arrangement with two ports (1 and
2). The ports are separated by a poppet, seated on a valve seat. The poppet is held in a closed
position (in the normally closed valve) under the action of a spring. Port 1 is connected to the
high pressure air supply, while port 2 is connected to the actuator or other pneumatic device.
When the push rod is pressed down against the spring pressure, the poppet opens up from the
seat, and allows the air to flow from port 1 to port 2.

In a pilot operated poppet valve, the poppet is moved under the action of a pilot pressure.
This has the advantage of remote operation, and also application of higher pressure for large
size poppet valves.

Suspended Seat type valve:

It has a suspended disc seat which performs the port opening and closing operations. The
advantage of the suspended seat valve is that the sealing can be performed with relatively
small switching movement.

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In this the main disc seat seal connects port P to either to port A or port B. The secondary seat
discs seal the exhaust port B whichever is not functional. Such valves are generally provided
with manual override buttons at each end of the spool to manually move the spool.

NON-RETURN VALVES:

Check valve:

Check valves allow free flow of air in one direction and block any flow in the reverse
direction.

The ball and poppet are held under light bias spring pressure against the seat. The valve
opens at low cracking pressures in the forward direction and allows the free flow of air. If the
air is stopped, the ball/poppet closes the valve under spring pressure and hence do not permit
any flow in the reverse direction. Check valves are quite useful in fluid power circuits and are
widely used in by pass lines to permit flow in one direction.

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Quick Exhaust Valve (QEV):

Quick exhaust valve is a special purpose valve used in pneumatic systems. It is designed to
increase the actuation speed of a cylinder, above that of the normal speed by the unrestricted
increased flow rate of air.

The basic principle of a quick exhaust valve is to allow a normal flow to the cylinder in the
supply line, while increase the flowrate (above the normal rate) in the return line. It basically
eliminates the entry of return/exhaust air through the usual DCV route, where flow passes
through the constraints of the tubes and valves.

It consists of a cylindrical body with three ports. The port P is connected to the pressure line
(inlet), the port A is connected to the cylinder, and port R is connected to the exhaust.
Though all the ports are interconnected, there is an intermediate resilient disc, which allows
the flow between only two ports at a time.

In operation, when the inlet line pressure is applied to the port P, the disc under pressure
opens-up to port A, while sealing the exhaust port. The openings in the disc are sufficient
enough to allow a normal flow rate from port P to port A, which causes the cylinder actuation
at the normal design speed. When the cylinder performs the return stroke the supply line is
blocked, because of this resilient disc springs back to its NC position thus blocking the port P.
at this position port A allows the return air, by connecting to the exhaust line (R). Since, it
gives a large opening between the cylinder return and exhaust port, under spring return (in a
single acting cylinder) or under the return line pressure (in a double acting cylinder), the air is

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exhausted freely through the valve. Due to this unrestricted excess flow rate the cylinder
retracts at a higher speed than the normal design speed.

Time Delay Valve:

The principle of construction of a time delay valve is similar to a 3/2 pilot operated valve.
The pilot valve is designed to operate against a spring pressure, once the pilot chamber
pressure exceeds the spring pressure. The main valve is held in a closed position (in a NC
type valve) by a bias spring. The flow rate can be set by the needle valve screw.

In operation, the air is allowed to the pilot chamber reservoir through the needle valve. The
reservoir size and the flow rate through the needle valve decide the time required to build-up
a pressure in the reservoir. Once the pressure reaches the spring pressure, it actuates the main
poppet valve and allows the main line pressure (P) to enter the cylinder port (A).

When the pilot pressure is removed, a flap check valve opens up and the pilot valve is vented
quickly to atmosphere. At the same time, the pilot valve retracts under spring pressure, the
main poppet valve closes (stopping the air supply from P to A), while the port A us
connected to the exhaust line R.

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 QUESTIONS FROM PREVIOUS YEAR QUESTION PAPERS:

DEC 2015/JAN 2016

1) Explain the laws for a perfect gas that governs the compressible nature of air.
2) Explain the basic structure of pneumatic system with its components.
3) Explain briefly with a neat sketch 3/2-way spool type direction control valve.
4) With a neat diagram, explain the construction and the functioning of the spool valve
or quick exhaust valve employed in pneumatic system.

JUNE/JULY 2016

1) What are the characteristics of compressed air? Explain them.

2) Sketch and explain structure of pneumatic control system.
3) Sketch and explain rod less cylinder.
4) What are flow control valves? Draw graphical symbols of FCV
5) Sketch and explain construction and principle of operation of a quick exhaust valve.
6) List different types of compressor. Explain with a neat sketch production of
compressed air.

DEC 2016/JAN 2017

1) Sketch and explain the cushion assembly for a pneumatic cylinder.

2) Differentiate between hydraulic and pneumatic systems.
3) Write short notes on:
i) Cylinder mounting arrangement
ii) Rod less cylinder
4) Explain with a suitable sketch:
i) Shuttle valve
ii) Quick Exhaust valve

JUNE/JULY 2017
1) What are the types of pneumatic actuators? With sketch explain the construction
and working principle of single acting cylinder.
2) Differentiate hydraulic and pneumatic system.
3) What is cushioning? Sketch and explain the cushioning of cylinder.

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4) With a neat sketch and symbol explain 3/2 direction control poppet valve.
5) Explain quick exhaust valve with circuit diagram.
6) Explain the three stages of preparation of compressed air.

DEC 2017/JAN 2018

1) State five disadvantages of using air instead of hydraulic oil.

2) Explain with schematic sketch of FRL unit with ANSI symbol.
3) Explain the characteristics of compressed air.

JUNE/JULY 2018

1) What is cushioning of cylinders? Why cushioning is necessary? Explain the working of

a typical cushioned cylinder.
2) Explain the different operational type principles used for the construction of Rod less
cylinders.
3) What is the function of a time delay valve? Explain the constructional features of
a typical time delay valve with neat sketch.

CRASH COURSE – MAY 2017

1) Give complete classification of pneumatic cylinder.
2) What is an FRL unit? Give the graphic symbol of it.
3) Explain with neat sketch solenoid controlled pilot operated direction control valve.

ONE TIME EXIT SCHEME – APRIL 2018

1) With a neat sketch explain the structure of pneumatic system.
2) Write a neat sketch explain FRL unit.
3) With a neat sketch explain rod-less cylinder.
4) Explain with a neat sketch:
i) Time delay valve
ii) Shuttle valve
iii) Poppet valve
iv) Solenoid valve

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 MODEL QUESTION PAPER – 1
1) Sketch and explain the mechanism of end position cushioning.
2) State the advantages and disadvantages of pneumatic systems.
3) Explain the different types of seals with neat sketch.
4) Explain with a neat sketch the construction and operation of a typical quick exhaust
valve to increase the actuation speed of a cylinder in a pneumatic system.
5) Explain the working of suspended seat type valve with a neat sketch.

MODEL QUESTION PAPER – 2

1) Explain the characteristics of compressed air.
2) Explain with a neat sketch the working of single and double acting pneumatic cylinder.
3) Explain with a neat diagram the structure of Pneumatic control system.
4) Explain with a suitable circuit diagram the application of a memory valve.
5) Explain the working of shuttle valve and time delay valve with a neat sketch.

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