ABSTRACT

Pneumatic system is a system that uses compressed air to transmit and control energy. Some
applications of the system in real world is in controlling train doors, automatic production
lines and mechanical clamps. Pneumatic system is widely used due to its high durability and
reliability, simplicity, safety and high adaptability to harsh environment. Through the
experiments conducted,a pneumatic system is set up and operated, operation of a 3-way, 2-
position directional control valve is verified and one-cycle reciprocation system is tested.

OBJECTIVES

1. Set up and operate a pneumatic system using the Conditioning Unit, a directional
control valve and a cylinder.
2. To verify the operation of a 3-way, 2-position directional control valve.
3. Set up and operate a one-cycle reciprocation system.

THEORY

Definition
Electro-pneumatic term is defined from words of electro, which mean electrical and
pneumatic, which mean air pressure. The electro-pneumatic system is an integration of
electrical and mechanical components with compressed air source.
Components
Electro-pneumatic controllers have a pneumatic power section. In an electro-pneumatic
control, the signal control section is made up of electrical components, for example, the
proximity switches, and the relays. The directional control valve behaves as an intermediary
between the electrical signal control section and the pneumatic power section in the
controller.
Switch
There are three (3) types of electrical switches used in the design of electro-pneumatic circuit.
They are:
i) Normally-opened (NO) contact switch.
ii) Normally-closed (NC) contact switch.
iii) Changeover contact switch.
Relay
Relay is an electrical device that contains a coil and one or more contact switches.
Solenoid Valve
Solenoid valve is an electro-mechanical device that built-in with a coil (solenoid) and a
pneumatic/hydraulic directional control valve (DCV).
Proximity Sensor
Proximity sensors are commonly used to monitor a process condition in a machine. For
instance, sensor is used to ensure the raw part was placed on a fixture, height of raw material
within control, etc. There are three types of proximity sensors:
1. Inductive sensor able to detect metal, especially mild steel.
2. Capacitive sensor able to detect most parts except low-density product.
3. Optical sensor able to detect bright surface reflectively except black / rough surface.

PROCEDURE

(A) Set up and operate a pneumatic circuit
1. Conditioning Unit, directional control valve and cylinder are mounted on the work
surface and connected as shown. The Conditioning Unit is connected to the NC
(normally non-passing) port of the directional control valve.

2. On the Conditioning Unit, the main shutoff valve and the branch shutoff valve at the
manifold are opened. A tip is screwed to the rod of the cylinder.
3. The regulator adjusting knob is pulled up to unlock the regulator and it is turned
clockwise to set the pressure at 200 kPa on the regulated Pressure Gauge.
4. The motion of the cylinder is observed and recorded.

(B) Verify operation of a 3-way, 2-position directional control valve
1. The status of the trainer is verified according to the procedure.
2. The circuit is connected as shown. The Conditioning Unit is connected to the NC
(normally non-passing) port of the directional control valve.

3. The main shutoff valve and the branch shutoff valve at the manifold are opened and
the pressure regulator is set at 100 kPa on the regulated Pressure Gauge.
4. The reading indicated by the Pressure Gauge is recorded.
5. The button on the directional control valve is pushed and the reading indicated by the
Pressure Gauge is recorded with this position of the button.
6. The shutoff valves is closed.
7. The circuit is modified by connecting the Conditioning Unit to the NO (normally
passing) port of the directional control valve.
8. The shutoff valve is opened and the pressure regulator is set at 100 kPa on the
regulated Pressure Gauge.
9. The reading is recorded.
10. The button on the directional control valve is pushed and the reading is recorded with
this position of the button.
11. The Conditioning Unit is connected to the OUT port of the directional control valve.
12. The shutoff valves are opened and the regulator adjusting knob is slowly turned
clockwise until some noise generated by compressed air can be heard.
13. The port where the compressed air flows is observed.
14. The button on the directional control valve is pushed and the observation is recorded.
15. The circuit is modified by connecting the Flow Control Valve to the NC port of the
directional control valve and the Conditioning Unit to the NO port.
16. The required shutoff valves are opened the pressure regulator is set at 200 kPa on the
regulated Pressure Gauge.
17. The Flow Control Valve is opened partially by turning the control knob three turns
counterclockwise.
18. The flow rate indicated by the flow meter is recorded.
19. The button on the directional control valve is pushed and the observation is repeated.
The flow rate indicated by the flow meter while the button is pressed is recorded.

(C) Setting up and operating one-cycle reciprocation system
1. The one-cycle reciprocation circuit is connected as shown. A tip is screwed to the
cylinder rod.

2. Magnetic Proximity Switch PX1 is mounted on the Double-Acting Cylinder so the
switch is activated when the cylinder rod is fully extended.
3. DC Power Supply is turned on.
4. The START pushbutton PB1 is shortly depressed. Pilot lamp L1 should turn on when
the electric circuit is working.
5. With my hand, the cylinder rod is pulled until it is fully extended. Pilot lamp L1 and
the pilot lamp of SOL-A should turn off if the circuit is operational.
6. The cylinder rod is retracted and the tubes are connected at the cylinder ports.
7. The Flow Control Valves are closed by turning the control knobs fully clockwise. By
turning the knobs two turns counterclockwise, each valve is opened. The mark on the
knobs is referred to help set the correct position.
8. The shutoff valve and the branch shutoff valve at the manifold is opened and the
pressure regulator is set at 400 kPa on the regulated pressure gauge.
9. The cylinder cycle is started by momentarily depressing the START pushbutton PB1.
The motion of the cylinder rod is observed.
10. The set screw on Magnetic Proximity Switch PX1 is loosened until the clamp is loose
enough to slip over the cylinder tie rod. The set screw is tightened after the switch is
positioned approximately at the middle of the cylinder.
11. The cylinder cycle is started by momentarily depressing PB1 while observing the
extension of the rod.
12. Relay contact CR1-A in rung 1 are removed. The circuit operation and its ability to
fully extend the cylinder rod is observed.
13. The Magnetic Proximity Switch PX1 is repositioned at the rod end of the cylinder and
the DC Power Supply is turned on.
14. The cylinder cycle is started by momentarily depressing the START pushbutton PB1
and the reaction time of the piston rod is measured. The results are entered in
appropriate cell and the measurement is repeated to validate the result.
15. The shutoff valves on the Conditioning Unit and the Quick Exhaust Valve is inserted
between Flow Control Valve FCV1 and the cylinder as shown. The tube used between
Quick Exhaust Valve and the cylinder must be as short as possible. The IN port of the
Quick Exhaust Valve must be ensured to be connected to the Flow Control Valve.

16. Shutoff valves are opened and step 14 are repeated.







DATA COLLECTION

EXPERIMENT 1: INTRODUCTION TO PNEUMATIC
Observation
1. At initial condition the rod of the cylinder didnt extend when the circuit is completed.
2. The rod of cylinder is extended when the button of directional control valve is pushed.
3. The rod of cylinder is extended when the button of directional control valve is pushed
for 5 seconds and released.
4. The cylinder is back to its initial position when the button is released for both cases.
EXPERIMENT 2: DIRECTIONAL CONTROL VALVES (DCV); NC VS NO VALVE
CONFIGURATION
Observation
A. Conditioning Units hose connected to NC port of DCV.
Initial Reading : 0 kPa
Final Reading : 100 kPa
B. Conditioning Units hose connected to NO port of DCV.
Initial Reading : 100 kPa
Final Reading : 0 kPa
EXPERIMENT 3 (A): DIRECTIONAL CONTROL VALVES (DCV); SELECTION
CAPABILITIES OF DCV.
Observation
1. The compressed air flow through the NO port of the DCV.
2. The compressed air flow through the NC port when the button of DCV is pushed.
EXPERIMENT 3(B):DIRECTIONAL CONTROL VALVES (DCV); SELECTION
CAPABILITIES OF DCV.
Observation
1. Flow Meter reading before button of DCV is pushed : 150 litre per meter
2. Flow Meter reading after button of DCV is pushed : 15litre per meter
EXPERIMENT 4&5: Introduction to Electrical Control of Pneumatic Systems & Basic
Electrically Controlled Pneumatic Circuits
Observation
1. Pilot Lamp L1 and Pilot Lamp SOL-A turned on when START button PB1 is pushed.
2. Both LI and SOL-A turned on when the cylinder rod is extended.
3. The cylinder is extended once the START button is pushed, but did not retract and
stays in the extended position.
4. The cylinder rod stops at one cycle only.
5. After modification (adding PB2-NC contact), pressing the PB2 will retract the
cylinder back to its original position.
6. Time taken for the cylinder rod to be retracted is faster with the Quick Exhaust Valve.
RESULTS AND DISCUSSION

EXPERIMENT 1: INTRODUCTION TO PNEUMATIC
A single acting cylinder has only one entrance port that allows compressed air to flow
through. Thus, thrust produce only in one direction. The rod of the cylinder do not extend
when we on the system. The button on the directional valve is pressed and the rod cylinder
extend. The pressurized fluid inside the cylinder will exert force and make the rod extend.
The rod cylinder returns to original position when the button is released. This is because the
compressed air is released inside the rod and spring force exerts on rod will make it to retract
to initial position. The motion of the rod cylinder shows that it convert fluid energy into
linear mechanical motion.
EXPERIMENT 2 & 3: DIRECTIONAL CONTROL VALVES
In double acting cylinder, a propelling force and a retracting force is produce by the air
pressure applied alternately to the surface of the piston.
When the main shutoff valve and branch shutoff valve at the manifold is opened, the reading
of the pressure gauge is 0kPa. Value about 100kPa is shown by the pressure gauge when the
button on the directional control valve is pushed. This flow path configuration corresponds
to a normally non-passing because when we leave (do not push the button), no fluid is pass
into the cylinder but when the button is pushed, the air is blown inside the cylinder. At this
moment, the valve is closed and air cannot pass when the air is at rest. When the operator is
energized (push the button), full flow is achieved.
After modified the circuit by connecting the Conditioning Unit to the NO (normally passing)
port, the pressure gauge shows the reading of 100kPa. When we push the button on
directional control valve, the reading shown at the pressure gauge is 0kPa. These flow path
configurations correspond to a normally passing valve because valves are fully open when
the operator is at rest and air will be at full flow. When the valve is energized (push the
button), the valve will closed and no air will pass.
Then the circuit is modified by connecting the Conditioning Unit to the OUT port of the
directional control valve. The compressed air flow through NO port at initial stage and when
the button of directional control valve is pressed the flow is through the NC port. This clearly
indicates that normal configuration of directional control valve is NO (normally passing)
which it determined by connect the output hose to Conditioning Unit.
The circuit is modified by connecting the flow control valve to the NC port. The flow control
valve is opened partially and the flow rate indicate by the flow meter is 150 litre/min. While
the button is pushed, the reading shows 15 litre/min. This confirmed that the directional
control valve allows the selection of a power source because this system is same like
regulator.
EXPERIMENT 4&5: Introduction to Electrical Control of Pneumatic Systems & Basic
Electrically Controlled Pneumatic Circuits
Based on observation and the guide provided, electro-pneumatic basically is a combination
between mechanical pneumatic and electrical circuit. The concept in mechanical pneumatic
is, the compressed air is supply to system through the shutoff valve and the regulator, from
here the shut off valve act as switch to let the air flow through the system. After that the air
flow to the regulator, this will allow operator to control the pressure that required by the
system. Next, again there is shut off valve to connect and disconnect the pneumatic system.
Then the compressed air connected to the spring solenoid by flow tube. From the solenoid it
connected to Flow Control Valve then go inside the Double Acting Cylinder. There is another
tube coming out from the Acting Cylinder connected to another FCV and going back to the
solenoid. Then the mechanical pneumatic system is completed.
For the electrical part we construct the circuit according to the ladder diagram given in
laboratory manual. The function of this circuit is to control the Double Acting Cylinder
position whether fully extend or not. Through this circuit the Magnetic Proximity Switch able
to detect whether the Double Acting Cylinder is fully extend or not. If the Double Acting
Cylinder was fully extend, the Magnetic Proximity Switch on the Double Acting Cylinder
will send the signal through the relay and power up the solenoid to change the direction of the
flow. In the solenoid, there is magnet where it will move against the spring when the current
is flow inside it. This action will move the valve at the solenoid and change the direction of
the air flow to let air go inside the cylinder and retract the position of the piston rod. This can
be identified when light indicator light up when the solenoid is power up.
The pilot lamp L1 and pilot lamp of SOL-A is turn off when we pull the cylinder rod until it
fully extended because the Magnetic Proximity Switch did not detect the piston position
inside the cylinder, underneath Magnetic Proximity Switch.

CONCLUSIONS

As for conclusion, we can set up and operate pneumatic and electro pneumatic system using
the equipment provided. The operation of the pneumatic circuit and electro pneumatic circuit
can be explained briefly from the aspect of theory and logically. The identification of the
pneumatic II system components also can be done. For recommendation, the replacement of
the components and equipment that are not really accurate in giving output should be
necessary. The objective is achieved.



APPENDICES