PNEUMATICS

Applied to the FIRST Competition

With Examples from the 2003 Xerox &

Webster School’s SparX Robot
Ken Buck
 What Does Pneumatics Offer?
ƒ Linear Motion
To provide a push or pulling force in a straight line
ƒ Create Vacuum
Double Acting cylinder – pressure on one side creates vacuum on
the other as the piston moves in the cylinder
ƒ Controlled Force
Based on the piston size (area) and pressure, a wide range of
constant force is available. Can be used to hold things in place
ƒ Combined with other cylinders & mechanisms
Can provide complex motion like the claw on a back hoe
 How was Pneumatics Used on SparX
2003 Robot?

ƒ Kicker Bar
Simple linear motion to extend the bar into position to engage the
lip of the totes
ƒ Acquisition System
Two cylinders acting in parallel combined with the claw arms,
pulled them together to clamp the tote so it could be grasped then
lifted
ƒ Elevation
Combined with a 4 bar link to both lift the kicker and acquisition
system, and to move it forward. Provided the kicking motion to
topple the first row of totes.
 Pneumatics– on the SparX 2003 Robot

Kicker Bar

Kicker Bar
Cylinder
Pneumatics– on the SparX 2003 Robot

Elevation
Cylinder
Pneumatics– on the SparX 2003 Robot

Acquisition
Cylinders
 Pneumatics– on the SparX 2003 Robot
Accumulator

Compressor Accumulator

Flow Restrictor

Plug Valve
Pressure Gage
Regulator
Plug Valve
Accumulator
 First Pneumatic Rules
ƒ Only items listed under the PNEUMATICS section of the Kit list may
be used to store, generate or transmit compressed air or vacuum
ƒ Only the allowed air cylinders may be used to generate vacuum.
ƒ You may only use pneumatic components from the pneumatics kit, no
extras are allowed.
ƒ Custom-made pneumatic components (fittings, air cylinders, pumps,
valves, etc) are not allowed.
ƒ Additional off-the-shelf pneumatic components are not allowed.
ƒ Primary Regulator set to maximum of 60 psi.
ƒ You can only use the 1 cylinder from the kit of parts plus the 3 free
cylinders = 4 total on your robot. (with 3 valves max)
ƒ Compressor must be powered through a Spike relay driven by the
system controller. Pressure switch cannot be wired in series with the
pump.
Pneumatics Parts Included in
FIRST Robotics Competition
Kit
These are the basic building blocks of the
system
The 2003 FIRST Demonstration Board
 SparX Experimentation Board

Preliminary
Pneumatics mounted
to prototype test
board

Enabled us to
experiment with the
pneumatic system
without the need for
functional controls
electronics and
software.
 Pneumatic System Partition
There are two independent sections of the
pneumatic system.
ƒ Primary System (High pressure side)
Contains the compressor and a tank for storing compressed air.
Also includes components to turn the compressor on and off which
maintains pressure within a control band. First sets this band
between 95 and 115 Psi.
ƒ Secondary System (Low pressure side)
Starts with the regulator which controls the lower pressure, to a
maximum of 60Psi. Also includes cylinders, the valves that control
them and all interconnecting tubing. Note that there can be more
than one Secondary System, and that they can run at a different
pressure. Note that cylinders and valves are Never connected to
the Primary System.
 System Operation – Primary Side
Pressure
Switch

Primary
Regulator

Primary Air Circuit Secondary Air Circuit To Pneumatic

60 Psi max Switches

Compressor Primary System Pressure Vs Time

Pressure With no loads applied
115Psi
Accumulator Volume
= 37.7 cubic inches
Over Pressure 95Psi

pressurizes the system

pressurizes the system
Relief Valve

Compressor re-
Compressor re-
System System
1) At power up, the compressor is energized through Compressor
Pressure drops Pressure drops
due to air leaks due to air leaks
the pressure switch. Pumps system
till Pressure
switch turns it
2) When the accumulator and Primary Circuit reach off
115Psi, the switch opens, turning the compressor off.
Time
3) If there are air leaks in the system, pressure will
bleed down to 95 Psi, at which point the switch will
close and the compressor will come on again.

This on and off cycle will continue as long as power is

available.
 Pneumatics Components

ƒ Compressor (& add’l components)

ƒ Connectors
ƒ Valves
ƒ Actuators (cylinders)
Pneumatic Components
Compressor Relief Valve
on Compressor

Pressure Switch
Pressure
Gauge

Accumulator
Plug Valve (2pcs.)
 Compressor Operation
Check Check
Valve Valve
Air In Air Out

Cylinder
When Piston When Piston
moves down, moves up, air
air is drawn is forced out of
past the inlet the cylinder,
check valve past the
into the exhaust check
cylinder valve into the
Piston primary system

Check Valves in the Inlet and Exhaust

Co nnecting Rod

Allow Air Flow in one direction

 Pneumatic Components
Regulator Made by Norgren Regulator Made by Monnier

Pressure
Switch

Primary Secondary
Regulator Regulator

Primary Air Circuit Secondary Air Circuit Secondary Air Circuit

60 Psi max with Different Pressure
Norgren is Monnier is
typically used typically used
Compressor Here Here

To Solenoids Running Cylinders @

Secondary Pressure
Accumulator Volume
= 37.7 cubic inches
Over Pressure
Relief Valve
Primary System Components

•Compressor and Relief Valve

•Tanks and Pressure Switch
•Gauge and Plug Valve
•Regulators with gauges
 Connectors
ƒ Many Variations Available
ƒ Size, Type of Connection,
Number of Ports

Tapered Pipe Thread

Generally Brass – Require Teflon Tape
Note – do not use Teflon tape on plastic threaded parts – it can strip the
threads off
 Fittings
Connection and Disconnection
 4-way Valves in the FIRST
Robotics Kit

ƒ Double Solenoid (detented)

ƒ Single Solenoid (spring offset)

(Festo)
 Pneumatics – Cylinders
Many
variations
of Bore and
Stroke
Available.
 Pneumatics

How it works
and how it applies to your robot
 Pneumatics – How it Works.
Valves
ƒ Directional control – controls the flow to the
actuator - analogous to relays or controllers
ƒ Flow control – controls the rate or the direction of
flow – analogous to resistors or diodes
ƒ Pressure control – controls the level of potential
energy – analogous to transformers
 Pneumatics – How it Works.
Actuators
Transform potential energy to work
ƒ Linear – often called cylinders – straight line but
can be configured to perform complex motion
 Pneumatics – How it Works.
ƒ Compressor - converts energy – electrical to pneumatic
ƒ Connectors - wires & terminals
ƒ Valves - relays, controllers
ƒ Directional control
ƒ Flow control
ƒ Pressure control
ƒ Actuators - Force to Motion: Motors, Solenoids, etc.
ƒ Linear – often called cylinders
ƒ Rotary – limited rotation – air motors
ƒ Clamps
 Pneumatics– Why?
The Advantages
ƒ Weight
equal or lighter than comparable alternatives
ƒ Simple
review the manual and you’re ready to go
ƒ Adjustable force
by adjusting the regulator pressure you can instantly adjust the
force developed by the cylinder.
ƒ Reliable & Durable
Compressor is shock mounted, fan cooled, and protected from
over pressure and over temperature. A very robust component.
 Pneumatics– Why?
The Advantages
ƒ Powerful
from 9 lbs to 180 lbs based on cylinder size and regulator
pressure – easily adjustable
ƒ Complete
all necessary parts included in the kit – 3 free cylinders available
if desired
ƒ Easy Mounting
all parts come ready to mount or tie wrap in place
ƒ Flexible & easy for last minute additions
add a valve or a cylinder, change routing quickly
 Air Supply
ƒ Ambient Air is compressed - In industrial applications the
air is ‘prepared’

ƒ Air Preparation – FRL – Filter - Regulator – Lubricator

ƒ Here’s Why ….
 Air Supply
ƒ Ambient air is compressed
But dust, dirt and water are included

In industrial applications, contaminants are removed

through the use of filters
ƒ Air preparation – FRL – filter - regulator - lubricator
 Air Supply - Filters
ƒ Mesh screens or sintered metal baffles
remove dirt
ƒ Spinning action forces water and
contaminants out of the air stream
ƒ Special filter materials can remove other
entrained contaminants like oil vapors
ƒ Fabric air filter is permanently mounted
on the side of the Thomas Compressor Example Industrial Air
Filter / Dryer
that comes in the First kit
 Air Supply - Regulator
ƒ Regulators Control Pressure
ƒ Relieving type in the FIRST kit
ƒ Non-Relieving type can trap pressure
The use of Regulators enables maximum
efficiency. Using the lowest pressure needed
draws the least power from the system.
For Cylinders used to provide simple
motion, Set Regulators to about twice
minimum pressure necessary to operate the
cylinder under load.
For Cylinders used to generate Force, set regulator pressure as
determined by dividing Force required by Piston cross sectional area.
 About Pressure
Safety MUST Always be considered.

Compressed Air is like a coiled spring

that can be routed to where it is needed
 About Pressure
ƒ The bore, stroke and motor horsepower control the
pressure from the compressor
ƒ The ratio of the uncompressed volume to the compressed
volume is the compression ratio

ƒ Relief valve and regulator control the working pressure

ƒ Compressed air is stored in the tanks as a reserve.

ƒ The higher the storage pressure and the greater the
volume, the more usable energy will be available
Facts About Pneumatics
 Facts about Pneumatics

ƒ Pressure – Potential Energy – Like Voltage

ƒ Lbs per in2 or Force per unit area
ƒ Absolute Pressure – 14.7 psia at sea level
ƒ Gauge Pressure – measured relative to ambient

ƒ Flow – Like electrical current

ƒ cfm or Volume per unit time
ƒ Scfm
 Facts about Pneumatics
ƒ Universal Gas Laws – Boyle’s Law
ƒ P1 x V1 = P2 x V2 if Temperature remains constant
ƒ That means if you cut the volume in half the absolute
pressure doubles – That’s how the Compressor works
Relationship between Gauge and Absolute
Pressure
PSIG 0 14.7 29.4 43.5 58.8
Gauge
PSIA 14.7 29.4 44.1 58.8 73.5
Absolute
 Facts about Pneumatics
ƒ Universal Gas Laws – Boyle’s Law
ƒ P1 x V1 = P2 x V2 if Temperature remains constant
ƒ That means if you cut the volume in half the absolute
pressure doubles – That’s how the Compressor works
P1*V1 = P2*V2 Where all pressures are absolute
~164.1 psig at sea level P1 = 30+14.7 = 44.7Psia
V1 = 4 cu ft
V2 = 1 cu ft
Then solving for P2 = (P1*V1)
V2

P2 = 44.7PsiA * 4 cu ft
1 cu ft

P2 = 178.8Psia - 14.7Psi = 164.1 Psi Gage

 System Operation – Primary Side
Pressure
Switch

Primary
Regulator

Primary Air Circuit Secondary Air Circuit To Pneumatic

60 Psi max Switches

Compressor Primary System Pressure Vs Time

Pressure With no loads applied
115Psi
Accumulator Volume
= 37.7 cubic inches
Over Pressure 95Psi

pressurizes the system

pressurizes the system
Relief Valve

Compressor re-
Compressor re-
System System
1) At power up, the compressor is energized through Compressor
Pressure drops Pressure drops
due to air leaks due to air leaks
the pressure switch. Pumps system
till Pressure
switch turns it
2) When the accumulator and Primary Circuit reach off
115Psi, the switch opens, turning the compressor off.
Time
3) If there are air leaks in the system, pressure will
bleed down to 95 Psi, at which point the switch will
close and the compressor will come on again.

This on and off cycle will continue as long as power is

available.
 Electrical Schematic for Pneumatics on SparX 2003 Robot

+12V Ground
Battery
Fuse

Spike Relay
Pressure Switch
+12V M+
A Compressor
M-

Ground
Control Zone
95 - 115Psi B

System
Controller Festo Solenoid
Extender
Spike Relay
A
+12V M+
A
M-
B
Ground
B

Spike Relay Dual Solenoid

A Kicker
+12V M+
A
M-
B
A
Ground
B
B

Spike Relay Dual Solenoid

A Claw
+12V M+
A
M-
B
A
Ground
B
B
Force Principles
 Force Principles
Gauge pressure works against
each square inch of piston surface

The greater the square inch surface of the fluid,

the less internal pressure will be developed.
 Force Principles
ƒ Universal gas laws - Pascal’s law
ƒ Pressure acts at right angles to the confining vessel –
that’s how a cylinder works
Transmission Principles
Valves Are In Control
 Valves Are in Control
ƒ Control Pressure
ƒ Relief Valves & Regulators
ƒ Control Flow
ƒ Check Valves (used on compressor)

ƒ Flow Controls
ƒ Needle Valves
4-way Valves - Control Flow
Spring
Solenoid

Passage A Passage B

Spool

Valve Body

Pressure Exhaust
Passage Passage
 4-way Valves in the FIRST
Robotics Kit

ƒ Double Solenoid (detented)

ƒ Single Solenoid (spring offset)

Valve Symbols
ƒ The 4-way valves included in the
kit are actually pilot-operated
valves.
ƒ Pilot-operators are actually 3-way
nnp (normally not passing or
normally closed) valves.
ƒ This allows low-power solenoids to
use the air pressure to switch the
main spool. Solenoids that would
actually move the main spool
would be large, heavy and
consume a lot of power.
Actuators – Make Things Move
 Actuators - Makes things move
ƒ Most common types of linear actuators
ƒ Double acting – single ended
All contain
zCylinder Barrel
z Piston
z Rod
zSeals
zSpring if used

ƒ Double acting - double ended

 Actuators - Makes Things Move
ƒ Most Common types of Linear Actuators
ƒ Single Acting - Single Ended

All contain
zCylinder Barrel
z Piston
z Rod
ƒ Single Ended - Spring Return zSeals
zSpring if used
Actuators - Construction & Operation

Basic Construction

Operation
 Actuators - Operation with Flow
Controls
Typically Flow Controls are mounted between the 4-way
valve and the cylinder as close to the cylinder as practical.

The internal check valve permits

free flow to the cylinder from the
valve and metered flow from the
cylinder to exhaust

Operation
 Actuators - Differential Areas
Force Consideration

• Consider the effective area on

which the pressure acts

• On single ended cylinders there

is a differential

• Don’t forget friction, and volume

of air needed relative to stored
volume in the accumulator tanks
Applying Your Components

You’ll get the best results by applying the

components carefully, following good
design practice and the following
information.
 Actuators - Angles

Power Factor
Angle A• Factor
10 .174
20 .342
45 .707
50 .766
60 .867
75 .966
90 1.0 Force T = Cylinder Force x sin A
 Actuators - Angles
ƒ Be sure to check all cylinder for freedom of movement.

ƒ With pressure off, manually move the cylinder and

mechanical components through the full stroke of the
cylinders.

ƒ Potential Interference Points

Actuators - Angles
Example: How much force must the cylinder
develop?
• Load 15 lbs - Boom Angle 50•
• Solution
• Step 1 – Force at right angles to support
weight =
15 x .643 (cos 50•) = 9.65 lbs = F2

• Step 2 – Effective Cylinder Force at right

angles to support weight = 9.65 x arm ratio
(17/5) =
32.79 lbs = F1

• Step 3 – Actual Cylinder Force acting at

30• = F1 / sin 30• = 65.59 lbs = F
Actuator (cylinder) Do’s and Don’ts
ƒ You do not have to fully extend a cylinder but you’ll need an
external stop.
ƒ Avoid side-loading – increases friction and wear

Weight or force applied at 90° angle to the rod

Wear, friction and leakage can occur

at the rod seal and at the piston seal

ƒ Avoid getting grit or metal shavings on the rod or in the

cylinder – causes abrasion and seal damage
ƒ Use flow controls for safety
Actuator (cylinder) Do’s and Don’ts
ƒ Cylinder Force to just balance the load
ƒ Push Force = π x cylinder radius2 x Pressure (psig)
ƒ Pull Force = Push Force - π x rod radius2 x Pressure (psig)
ƒ Use roughly twice the balance force for good control.

ƒ Teams may order additional cylinders (including spares) for

rapid delivery using the FAX form on the back of the manual.
¾”, 1-1/2” or 2” bore are available – see form in the manual
for available strokes

ƒ Avoid leaks – reduces available energy

Actuators – Mounting Thoughts
Example: Arm to be raised by Cylinder

• Determine overall length of retracted

cylinder

• Draw an arc from the mounting point on arm

• Determine overall length of extended

cylinder

• Draw an arc from the mounting point on arm

• Where arcs intersect is the mounting point

• Check for intermediate interference

 Calculating Cylinder
Dimensions

ƒ Based on the drawings in the pneumatic manual

ƒ Retracted length from pivot pin to clevis hole =
ƒ Base dimension +
ƒ Stroke length +
ƒ Locking nut +
ƒ Clevis dimension
ƒ Extended length from pivot pin to clevis hole =
ƒ Retracted length plus stroke
 1.5” Bore Cylinder

z Base Dimension = 4.38 +

z Stroke Length = ? +

z Locking Nut = .25 +

z Clevis Dimension = 1.31

Retracted Length = 4.38 + Stroke + .25 + 1.31 = 5.94 + Stroke

Extended Length = 5.94 + (2 x Stroke Length)

 System Example From SparX 2003 Robot
Kicker Cylinder Claw Cylinders (2)
3/4 in dia x 10 in long 3/4 in dia x 6 in long
Volume = 4.4 cubic inches Volume = 2.65 each
5.3 total cubic inches

Exhaust
Primary
Exhaust Exhaust
Regulator Valve

Valve
Secondary Air Circuit
60 Psi max
Exhaust Exhaust
Valve

Exhaust
Elevation Cylinder
2in dia x 12 in long The graph below shows how the
Volume = 37.7 cubic inches secondary sees relatively consistent air
pressure, while the primary side has
wide swings in pressure.
Pressure Primary & Regulated System Pressure Vs Time
With different loads applied Always connect your cylinders to the
regulated side to avoid these wide
Primary Pressure
swings in pressure
115Psi

101.4Psi
95Psi
90Psi 89.8Psi
Compressor re-pressurizes the system

80Psi
70Psi
Regulated Secondary Pressure
60Psi
pressurizes the system

50Psi 50.2Psi
40Psi 42.7Psi
Close Kicker Bar
Open Kicker Bar

Compressor re-

30Psi Compressor
Pumps system Open Elevation Open Claw
Close Claw

Close Claw
Open Claw

Open Claw

20Psi till Pressure Then Compressor Open Kicker

switch turns it re-pressurizes the system Open Elevation
10Psi off
0Psi
Time
 Tips & Tricks
ƒ Minimize leaks (better yet,
remove them completely) by
careful use of teflon® tape and
careful assembly of tubing and
fittings. Teflon tape should start
two threads back and wrap in
the direction of the threads.
ƒ With no movement taking place
the compressor should charge
the tanks and then shut off. It
should not restart until a valve
and cylinder is operated.
ƒ Use the compressor
vibration isolators. The
compressor is a
reciprocating device and
will cause sympathetic
vibrations throughout your
assembly unless they are
used.
ƒ When ordering custom
cylinders, use extreme care
in completing the form,
both on the address and
models ordered.
 Tips & Tricks
ƒ The Pressure Switch
contacts must be used as
inputs to the controller. They
cannot handle the amperage
of the compressor.
ƒ The Norgren Regulator
should be first with the
Monnier unit used after that
if needed.
ƒ Make sure you have
adequate pilot pressure for
the valves.
ƒ When using the double
solenoid valve, energize only
one at time.
ƒ The fittings for the
FESTO valve are
different, use them in
that valve only. Fittings
are not required in the
exhaust ports unless the
circuit requires them.
ƒ Always stay clear of
cylinders in motion.
Until compressed air is
being metered, flow
controls do little to
control speed.
 Review Questions
ƒ Which statement is true ?
1. There is no benefit in using a regulator to reduce pressure.
2. You’re “stuck” with the cylinders that come in the kit.
3. A pressurized cylinder at rest cannot apply force.
4. You can save some inputs on the controller by forgetting
about the pressure switch and running the compressor
continuously.
5. There is no such thing as a pneumatic “diode” or one-way
valve.
6. A 2” bore cylinder at 100 psig yields 200 lbs of force.
7. None of the above.
 Review Questions
ƒ Which statements are true ?
1. There is no benefit in using a regulator to reduce pressure.
2. You’re “stuck” with the cylinders that come in the kit.
3. A pressurized cylinder at rest cannot apply force.
4. You can save some inputs on the controller by forgetting
about the pressure switch and running the compressor
continuously.
5. There is no such thing as a pneumatic “diode” or one-way
valve.
6. A 2” bore cylinder at 100 psig yields 200 lbs of force.
7. None of the above.
Correct answer – None of the above.
Review Question - Statements
1. Using the lowest pressure that will run your system, uses the
least volume of air saving running time on the compressor and
time on the battery.
2. You can order custom cylinders with the form that comes with
the kit.
3. A pressurized cylinder applies force based on pressure and
piston area.
4. You would drain your battery too quickly. If there is no
movement, the compressor doesn’t run, even though force is
being exerted. Use the pressure switch.
5. A pneumatic diode is called a check valve.
6. The force is equal to π x cylinder radius2 x Pressure (psig) – or
3.14 x 12 x 100 psig or 314 lbs
 Review Questions

ƒ Which statement is correct ?

1. Your pneumatic kit is complete, although custom
cylinders can be received quickly.
2. You need to supply an extension cord to power the
compressor from a wall outlet.
3. Because air is weightless, it will reduce the weight of
your robot when pressurized.
4. The pressure switch is only included to sound an alarm
if ambient pressure falls.
 Review Questions

ƒ Which statement is correct ?

1. Your pneumatic kit is complete, although custom cylinders can
be received quickly.
2. You need to supply an extension cord to power the compressor
from a wall outlet.
3. Because air is weightless, it will reduce the weight of your robot
when pressurized.
4. The pressure switch is only included to sound an alarm if ambient
pressure falls.
Correct answer – 1. The pneumatic kit is complete.
 References
ƒ Slides based on "Pneumatics and the FIRST
Competition" by John R. Groot of the Fluid Power
Educational Foundation, taken from the First web
site
ƒ SparX content added by Ken Buck
Ken.Buck@usa.xerox.com
 Interesting Links
Fluid Power Educational Nason Corp SMC Pneumatics
Foundation www.nasonptc.com www.smcusa.com
www.fpef.org
Bimba Manufacturing Lord Corp Fluid Power Dist. Ass’n
www.bimba.com www.lordmpd.com www.fpda.org
Clippard Instrument Lab. Monnier, Inc. Fluid Power Society
www.clippard.com www.monnier.com www.ifps.org

Wika Norgren Nat’l Fluid Power Ass’n

www.Wika.com www.norgren.com www.nfpa.com

Festo Parker Fluid Power Journal

www.FluidPowerJournal.com
www.festo.com www.parker.com