Electro-Pneumatic

Module 1: Introduction to Electropneumatics

PREPARED BY

Academic Services
August 2012

Applied Technology High Schools, 2012

ATM-414 Electro-Pneumatics

Module 1: Introduction to Electropneumatics

Module Objectives
After the completion of this module, the student will be able to:
1- Explain all safety precaution when working with electro-pneumatics.
2- Explain the concept of signal flowing in electro-pneumatics.
3- Identify the advantages and disadvantages of the elector-

pneumatics.

Module Contents
Sr

Topic

Page No.

Introduction to electro-pneumatics

Signal flow in electro-pneumatics

Advantages of electro-pneumatic systems

Components of electro-pneumatic system

Safety and operation

12

Practical task 1

13

Practical task 2

17

Practical task 3

18

References

24

Module 1: Introduction to electro-pneumatics

ATM-414 Pneumatic systems

1
Introduction to electropneumatics
Electro-pneumatic is widely used in
many

areas

of

industrial

automation. Production, assembly,

and packaging systems worldwide.
These

systems

are

driven

by

electro-pneumatic control systems.

Fig.1.1 (a) and Fig1.1 (b) show
different applications

of

electro-

pneumatic machines.
In

(a)

electro-pneumatics,

pneumatic

components

the
are

controlled by using electrical and

electronic circuits. Electronic and
electromagnetic sensors, electrical
switches and industrial computers
are used to replace the manual
control of a pneumatic system.

(b)

Fig.1.1
(a): Milk filling machine
(b): Yogurt filling machine

Module 1: Introduction to electro-pneumatics

ATM-414 Electro-Pneumatics
`
2

Signal flow in electro-pneumatic control system

The signal flow diagram of Fig. 1.2 illustrates the signal flow within an
electro-pneumatic system.
1. Signal input: This signal is usually generated from sensor or switch.
2. Signal processing: the signal is processed in the processing station such
as OR gate, AND gate or time delay valve.
3. Signal output: the signal forms as a link between the signal control
section and the power section
4. Command execution: it takes place at high power level either for:

High speed-fast ejection of product.

Apply high force as in power presses.

Fig. 1.2: Signal flow and components of an electro-pneumatic control

system

Module 1: Introduction to electro-pneumatics

ATM-414 Pneumatic systems

3

Advantages of electro-pneumatic systems:

Below are some advantages of electro-pneumatic systems

1. Greater reliability.
Less moving parts subjected to wear compared to mechanical
control systems.
2. Reduced installation complexity.
Less components and hoses, leads to less effort in planning and
commissioning especially with large and complex systems.
3. The control system can be easily modified and adapted.
It is easier to change wiring and modify programs rather than
changing mechanical components and hose networks.
Example: the AND gate is replaced with logic and through using
electrical switches.
4. Easy handling.
Less complexity
5. Secure mounting.
Fewer hoses
6. Environmentally-friendly coupling system.
Less lubrication require
4

Components of electro-pneumatic system

The electro pneumatic system is normally consists of the following items:

1. DC power supply.
2. Switches.
3. Relays.
4. Solenoid valves.
5. Sensor.

Module 1: Introduction to electro-pneumatics

ATM-414 Electro-Pneumatics
4.1

DC Power Supply

The power supply is used to reduce and convert the 230 V AC to a 24 V DC

(inside ATHS laboratories) as shown in Fig.1.3

Figure 1.3 power supply

The power supply components which are shown in Fig. 1.4 have the
following functions:

The transformer reduces the main voltage (230 to 24 volt).

The rectifier converts the AC voltage to DC voltage.

The stabilizer is used to smooth and maintain constant voltage at the

output

Fig.1.4 electric diagram of the power supply

The following criteria play commonly an important role is selecting the
power supply:

The magnitude of voltage and current it can supply.

How stable its output voltage or current is under varying load

conditions.

Whether it provides continuous or pulsed energy.

Module 1: Introduction to electro-pneumatics

ATM-414 Pneumatic systems

4.2

Switches

Switches are installed in an electric circuit to connect or interrupt the

electric current.
These switches are divided into:
1- Control switches: keep the selected position such as detent switches.
Push button switches: maintain the selected position as long as the switch
is activated.
In this module, three types of switches will be discussed:
a. Push button switches.
b. Detent switches.
c. Limit switches.
(a)

Push button switches

These switches are activated manually and used connect or disconnect the
electric current in he control circuit. There are three typed of the push
button switches:
1- Normally

open

contact

(make)
In the case of a normally open
switch Fig.1.5.a, the circuit is
open if the switch is in its initial
position

(a)

(b)

Pressing the pushbutton results in

closing the circuit and then the
current will flow to load. When
the plunger is released the spring
will returns the switch to it initial
position.

Module 1: Introduction to electro-pneumatics

ATM-414 Electro-Pneumatics
2 Normally

close

contact

(break)
In the case of the normally closed
switch Fig. 1.5.c, the circuit is
closed when the switch is in its
initial

position.

interrupted
pushbutton.

by

The

circuit

pressing

Fig.1.5.d

shows

(c)

is

(d)

the
the

ISO symbol of the push button N/C.

2

3 Changeover contact (two-

way)

The change over contact Fig. 1.9-c

combines

the

function

of

the

(e)

(f)

normally open and normally closed.

Changeover contacts are used to
close one circuit and open another
circuit in one switching operation.
In the (ATHS) labs, these types of
switches are combined in one switch
block as illustrated in figure 1.5.g.

(g)
Fig.1.5:
(a): push button switch (N/O)
(b): ISO symbol of the normally
open push button switch
(c): push button switch (N/C)
(d): ISO symbol of the normally
closed push button switch
(e): changeover switch (two way)
(f): ISO symbol of the changeover
switch
(g): Switch block

Module 1: Introduction to electro-pneumatics

ATM-414 Pneumatic systems

b

Detent switches

These

switches

keep

the

selected

position; the switch position remains

unchanged until a new switch position
is selected. It is called detent switch or
a

latching

switch.

Fig.1.6.a

and

(a)

Fig.1.6.b show the ISO symbol of the

normally

open

normally

detent

closed

switch

detent

and

switch

respectively.
Detent switches also designed to be as
normally

open,

normally

closed

(b)

or

changeover switches.
In the (ATHS) labs, the detent switches
are included in the same switch block
with pushbutton switches, as shown in
Fig. 1.6.c

(c)
Fig. 1.6:
(a): ISO symbol of normally
open detent switch
(b): ISO symbol of normally
closed detent switch

Limit switches

(c): Switch block

The limit switch (Fig.1.7.a) is actuated

when a machine part or a work-piece is
in

certain

position.

Normally,

actuation is affected by a cam or

cylinder piston.
Limit switches are normally changeover

(a)

Module 1: Introduction to electro-pneumatics

(b)
9

ATM-414 Electro-Pneumatics
contacts

and

according

to

can
the

be

connected

required

control

circuit. The limit switch can be used in

circuit

according

to

one

of

the

following:
Normally open switch
Normally closed switch
Changeover switch
.

Fig. 1.7
(a): internal construction of the
limit switch
(b): ISO symbol of the limit
switch
(c): picture of the limit switch

10

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4.3
A

Relays

relay

is

defined

as

an

electromagnetically actuated switch.

When the voltage is applied to a
solenoid coil terminals (A1, A2) in
Fig.1.14,

it

will

become

an

electromagnet which in turn attracts

the contacts of the relay either closing

(a)

or opening them.
The spring returns the contacts to the
initial

position

immediately

after

disconnecting the voltage at the coil

terminals.

(b)

An ISO symbol of the relay and a lab

relay block is also illustrated in the
same figure.
Some advantages of a relay that:

It can be used to switch one or

more contacts.

To switch a high current circuit with

a low current circuit.

(c)
Fig. 1.8:
(a): Internal structure
(b): ISO symbol of the relay
(c): Relay block

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5. Safety and operation

The following points should be observed while working with electropneumatic systems:
1. Pressurized

air

lines

that

become detached can cause

accidents. Switch off pressure
immediately.
2. First connect all tubing and
secure before switching on
the compressed air.
3. Cylinders
retract

may
as

advance

soon

as

or
the

compressed air is switched

on.
4. Do not operate the electrical
limit switch manually during
fault

finding

(use

tools

only).
5. Limit switches should be fixed
in

such

way

that

they

contact the trip cam of the

cylinder

only

in

the

determined direction.
6. Do not exceed the permissible working pressure.
7. Use only low voltages of 24 V.
8. Switch off the air and voltage supply before disconnecting the
circuit.

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ATM-414 Pneumatic systems

6. Practical Task 1
Title:
Controlling an electric bulb lighting
using different types of switches
Objectives:

Understanding and using the DC

power supply.

(a)

The student should be able to use of

the pushbutton switches (NO and
NC).

The student should be able to use of

detent switches (NO and NC).

The student should be able to use of

changeover switch.

The

student

construct

the

should

be

circuit

able

using

to

(b)

the

FluidSim software
Background:
The student should know how to use
the Pushbutton, detent and changeover
switches that will be used to switch
on/off a lamp using different circuit
configurations.
(c)

Required components:
1- DC power supply (Fig.1.9.a)
2- Indicator unit (Fig.1.9.b)
3- Switch block (Fig.1.9 c)
4- Limit switch (Fig1.7 c)

Fig. 1.9:
(a): Dc power supply
(b): Indicator block
(c): Switch block

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ATM-414 Electro-Pneumatics
Procedures:
1. Prepare the components according to
the components list.
2. From

the

switch

block,

use

pushbutton switch to connect the first

two circuits as in Fig.1.10.a

Pushbutton switch, normally open.

Press the switch on/off and explain
what happens to the lamp.

Pushbutton, Normally closed switch.

Press the switch on/off and explain

N.O

what happens to lamp.

NC
(a)

..
3. From the switch block, use a detent
switch

to

connect

the

second

two

circuits as in Fig.1.10.b

Detent switch, normally open. Press

the switch and note what happens to
the lamp.

N.O

N.C.
(b)

14

Module 1: Introduction to electro-pneumatics

ATM-414 Pneumatic systems

Detent switch normally closed. Press

the switch and note what happens to
the lamp.

..

4. Use a limit switch (as a changeover

switch) to connect the circuit as in
Fig.1.10.c
Press the switch and see how the switch
is used to control two circuits at a time.
Write your comments.

(c)

Fig. 1.10:

(a): Push button switch

(b): Detent switch

(c): Changeover switch

..
5. Turn the power off.
6. Dismantle and tidy up.
Conclusion
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ATM-414 Electro-Pneumatics
7. Practical Task 2
Title:
Indirect control of a lamp using a
pushbutton switch and a relay.
Objectives:

Introduce the students to the use of

lab equipment.

Introduce the students to the use of

DC power supply.

Introduce the students to the use of

the pushbutton switches (NO and
NC).

Introduce the students to the use of

the relay and the associated
contacts (NO and NC).

Background:
The relay is an electromagnetically
operated switch; it will be used to
indirectly control a 24V lamp through
a pushbutton switch.
Required Components:
5- DC power supply
6- Indicator unit
7- Switch block
8- Relay block

16

Module 1: Introduction to electro-pneumatics

Relay block

ATM-414 Pneumatic systems

Procedures:

+24V

1. Connect the circuit according to circuit

shown in Fig.1.11.a, so the relay is a

normally open.

2. Switch on /off the pushbutton switch

A1

and observe the lamp and also the LED

of

the

relay

block.

Explain

what

3
K1

K1
A2

happens to the lamp?

0V

..

(a)

3. Replace the pushbutton switch with a

detent switch and repeat the same

+24V

steps. Explain what happens to lamp.

3

K2

K2

shown in Fig.1.11.b, so the relay is in a

normally close mode.

A1

4. Connect the circuit according to circuit

A2

0V

5. Switch on/off the pushbutton switch

and observe the lamp and the LED of
the relay block. Explain what happens

(b)

to lamp.
..

Fig. 1.11:

(a): Relay-Normally open

(b): Relay-Normally closed

Module 1: Introduction to electro-pneumatics

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ATM-414 Electro-Pneumatics
6. Turn off the power
7. Dismantle and tidy up.
Conclusion
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8. Practical Task 3:
Title: Opening/closing the flow in a pipeline
The double acting cylinder (1A) in Fig. 1.12 is used to open and close the
main valve in a pipeline. Draw an electro-pneumatic circuit to control the
movement of cylinder (1A).
Hint: The valve is opened by pressing the pushbutton switch. When the
pushbutton is released the valve is closed.

Fig. 1.12

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Module 1: Introduction to electro-pneumatics

ATM-414 Pneumatic systems

Procedures:
1. Draw the elector-pneumatic circuit using the FluidSim software
2. Test the circuit functions against any errors or mistakes.
3. Construct the circuit on the workstation
4. Write down your notes and observations.
Pneumatic circuit

Electric circuit

Observations
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Students notes
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Module 1: Introduction to electro-pneumatics

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Class work
1. Name three electrical components that will be used in the lab.

2. What is the function of a D.C. power supply?

3. What are the main components of the D.C. power supply?

4. List the main types of switches in terms of function.

5. Explain the difference between a push button switch and a detent switch.

6. Explain the difference between a pushbutton normally open switch and a

pushbutton normally closed switch.

Module 1: Introduction to electro-pneumatics

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ATM-414 Electro-Pneumatics
7. Draw the ISO symbol of the following components:
a- Detent pushbutton switch, N/C and N/O
N/C

N/O

b- Changeover switch

c-Relay

22

Module 1: Introduction to electro-pneumatics

ATM-414 Pneumatic systems

Home Work
The circuit below illustrates a relay controlling three lamps indirectly,
answer the following questions:

1. What is the type of switch S1?

2. How many relays are there in the circuit?

..
3. What is the meaning of the symbols below circuit 1 and circuit 4?

..
4. Explain what happens when switch S1 is activated.

Module 1: Introduction to electro-pneumatics

23

ATM-414 Electro-Pneumatics
9. References

24

1.

Electro-pneumatic text book TP 201 2005 Festo

2.

Electro-pneumatic work book TP201 2005 Festo

3.

Electro-pneumatic work book TP202 advanced level Festo

Module 1: Introduction to electro-pneumatics