Pneumatic Training Guide

Training on
Industrial
Pneumatics
NFI – Industrial Automation
& CAD Training Academy
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What Does Pneumatics means?
Comes from Greek Word: “Pneumatikos “
means Wind or breathe
Pneumatics is movement
by compressed Air
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Pneumatics in Day to Day Life
It is put to a wide variety of uses such as dentists drills, automatic doors,
brakes on lorries and hammer drills used at roadwork's.

Who Discovered the Idea of Pneumatics?
German Physicist &
Engineer –
Otto von Guericke
(1602-1686)
17th
Century
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Magdeburg Hemispheres
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Magdeburg Hemispheres

Force & Pressure
Illustration of pressure varying with temperature.
Pressure-temperature law

Boyle’s law or Boyle–Mariotte law
the absolute pressure and volume of a given mass of confined gas are inversely
proportional, if the temperature remains unchanged within a closed system.
Thus, it states that the product of pressure and volume is a constant for a given
mass of confined gas as long as the temperature is constant
pV= k
Pressure = Voltage
Volume = Capacitance
Flow rate = Current
Flow Restrictions = Resistance

Typical Units of Pressure
The SI unit for pressure is the Pascal (Pa), equal to one newton per
square meter (N/m2 or kg·m−1·s−2).

Typical Units of Air Flow
CFM = Cubic feet per minute
Cubic meter per hour = M*M*M/Hour
Litres per minutes = l/min

Basic Pneumatic System
How Bike Pump Works?

Basic Industrial Pneumatic System

Basic Industrial Pneumatic System
Electrical Motor
IT ACTIVATEWHEN PRESSUREIS
ABOVECRACKINGPRESSURE
Pneumatic Pressure Source
Pressure Relief Valve 2
Double-Acting Cylinder
Gas-loaded Accum ulator w ith separator
0.00 Bar
Pressure Indicator
Exhaust
Compressor With Left Shaft/Variable
Solenoid

Two Sections of Pneumatic System
1. Air Production & Distribution System
2. Air Consuming System

Components of
Air Production System
1. Compressor
2. Electric Motor
3. Pressure Switch
4. Check Valve
5. Tank
6. Pressure gauge
7. Auto Drain
8. Safety Valve
9. Air Dryer
10. Line Filter

Compressor
1. Reciprocating Type – Piston & Diaphragm
2. Rotary - Vane & Screw Type
Converts mechanical energy into pneumatic energy

Compressor
Single Stage
Two Stage

Compressor
Diaphragm
Inlet Outlet
Inlet
Outlet
Crank

Compressor
Eccentrically mounted
rotor

Compressor
Helical Screws rotating
Opposite to each other

Compressor Ratings
Typical factors determining nature of compressor
Displaced Volume or Displacement = Q (l /min) or (l/rev)
Nominal Speed = in rpm
Maximum Pressure = in Bar or psi
Tank Capacity = in litres
Maximum Flow = l/min or l/sec
Fixed Type Variable Type

Components of
1. Compressor
2. Electric Motor
3. Pressure Switch
4. Check Valve
5. Tank
6. Pressure gauge
7. Auto Drain
8. Safety Valve
9. Air Dryer
10. Line Filter
For Auto Cut off at required
Pressure

Components of
For Auto Cut off at required
Pressure

Components of
Check Valve
Check Valve Spring Loaded

Components of
1. Compressor
2. Electric Motor
3. Pressure Switch
4. Check Valve
5. Tank
6. Pressure gauge
7. Auto Drain
8. Safety Valve
9. Air Dryer
10. Line Filter
0.00 Bar
To measure Inlet & Outlet Pressure

Components of
1. Compressor
2. Electric Motor
3. Pressure Switch
4. Check Valve
5. Tank
6. Pressure gauge
7. Auto Drain
8. Safety Valve
9. Air Dryer
10. Line Filter
To remove water inside the Compressor

Components of
1. Compressor
2. Electric Motor
3. Pressure Switch
4. Check Valve
5. Tank
6. Pressure gauge
7. Auto Drain
8. Safety Valve
9. Air Dryer
10. Line Filter
Pressure Relief Valve

Components of
Drying agent such as
Dehydrated chalk
or
Magnesium chloride
It reacts with moisture
(in air) to form solution
which is drained from
the bottom

Components of
to remove contamination, oil
vapors from the compressor
and water from the air

Components of
Air Production
System
Combining All the components together
0.00 Bar
Pressure Indicator
Electrical Motor
Pneumatic Pressure Source
Air Dryer
Filter
Lubricator
Cooler

Two Sections of Pneumatic System
1. Air Production & Distribution System
2. Air Consuming System
Elements of Air Consuming System
1. Actuators – Pneumatic Cylinders
2. Valves – Directional Control Valves (DCV)

Air Consuming Section
Actuators – Pneumatic Cylinders
Used to produce linear motion
Single Acting Cylinder

Single Acting Cylinder
Single-Acting Cylinder With Spring Return
Single-Acting Cylinder With Spring Extend

Double Acting Cylinder

ble-Acting 2-Cushion Cylinder
On large cylinders, the shock forces
can be absorbed by an air cushion
that decelerates the piston over the
last portion of the stroke
Double Acting Cylinder with Cushion

A double ended piston rod makes a cylinder stronger against side
load, as it has two bearings at the widest distance possible. This type
of cylinder is often mounted with rods fixed and the cylinder itself
moving to displace a part.
Double Acting Double Rod Cylinder
Double-Acting Double-Rod Cylinder

Actuators – Other types of Cylinders
Used to produce rotary/linear motion
Rotary Actuator- Vane Type Rodless Cylinder

Piston Force
Dependant on the air pressure, the cylinder diameter, and the frictional
resistance of the sealing components.
Fth = A . p
Fth = Theoretical piston force in N.
A = Useful piston area in cm².
p = Operation pressure in kPa.
Fn = Effective piston force in Newton (N)
FR = frictional force (3-20%) in Newton (N)
Fn = A. p – (FR+FF)
Single Acting Cyl.
Fn = A. p – FR
Double Acting Cyl.

Valves – Directional Control Valves (DCV)
1. Allowing the passage of air and directing it to particular
air lines
2. Canceling air signals as required by blocking their passage
and / or
3. Relieving the air to atmosphere.

3/2– Directional Control Valves (DCV)
?
3/2 Spring return
Valve NC
?
3/2 Spring return
Valve NO

5/2 Spring return
Valve NC
5/2 Spring return
Valve NO
?
?

??
To stop the cylinder in between
5/3 Double Button Spring Return Valve
0.00 Bar

Pneumatics Exercises
1) Draw a pneumatic circuit to actuate two Single Acting Spring Return
cylinder with one 3/2 Valve
2) Draw a pneumatic circuit to actuate Double acting Cylinder with 5/2
Valve
? ?

Flow Control Valves: Throttle Valve
To control the flow
Fixed Throttle
Valve
Variable Throttle
Valve
Non Return
Throttle Valve
Variable Non Return
Throttle Valve

Flow Control Valves: Check Valve
The check valve allows oil flow in one direction and blocks it
in the opposite direction.
Check Valve
Spring Loaded
Check Valve
Pilot to Open
Check Valve
Pilot to Close
Check Valve

Shut off Valves
The shut-off valve can isolate 2 distinct lines in an hydraulic
circuit
Shut off Valve
Normally Open

Vacuum Generator
To generate vacuum
Inlet
Exhaust
Vacuum Pressure
Vacuum Cup

Pneumatics Flow Lines & Connections
Silencer Pneumatic Pressure
Source
Pneumatic Exhaust
Pneumatic T Connector Pneumatic other Fittings Pneumatic Pipes

Electro- Pneumatics
Including Electronics/Electrical Circuits in Pneumatics Circuit to control
automatically – typically referred to DCV

Electro- Pneumatics
Including Electronics/Electrical Circuits in Pneumatics Circuit to control
automatically – typically referred to DCV
Solenoid
?
Solenoid Ratings: 24 VDC, 220 VAC

Pneumatics Exercises
1) Draw an Electro- pneumatic circuit to actuate Single acting cylinder with
3/2 solenoid valve actuated by Toggle switch
2) Draw a pneumatic circuit to actuate & latch Double acting Cylinder with
5/3 Spring return Solenoid Valve
? ?

Pneumatics Applications

Pneumatics Applications
– Pick & Place Robotic Arm driven by PLC

Festo Pneumatics Applications

FREE PLC Course: -
“Learn PLC in a DAY”
Automation Knowledge Base

rajvir@nfiautomation.org
9988808455
thank you
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