Pneumatic Control and Automation

Pneumatic Control and Automation
Fluid power is commonly used in industry to move linear and rotary actuators, and also to
transmit control signals that allow a series of events to take place in a pre-determined order.
Hydraulic power using oil is preferred when large forces or loads are involved, or if precise
positioning is required, as oil is considered incompressible. Pneumatic power is faster, as air
is lighter to move and produces less friction, but as we are limited to a typical air supply
pressure of 120 psi (8 bar), it is normally used to move lighter loads, unless very large
actuators are used (Force = pressure x area). As air is compressible, precise positioning is not
possible. However, it has another distinct advantage of being safe to use in hazardous
situations where explosions or fires may occur.
The following designs will illustrate how pneumatics can be used to provide linear motion,
starting with a very cheap and simple circuit, and then gradually increasing in complexity
and sophistication in order to demonstrate the use of safety interlocks and automation in
mechanical- and electro-pneumatic systems.
A typical design scenario is presented with each design, which normally starts in the bottom
left-hand corner of the page with the service units (compressed air source, filter, regulator,
lubricator and isolation switch). The design then rises diagonally to the top right-hand corner
with input, processing and final control functions in horizontal layers for easy recognition,
and culminating in output or actuation. A numerical system using 0 for service equipment, 1
for devices operating the first actuator, and 2 for devices operating the second actuator,
followed by a second number to differentiate between components, is used to make
schematics easy and logical to follow. Sometimes a letter (S for input switch, V for valve and
A for actuator is used between the numbers. An example would 1.2 or 1.V.2 which would
indicate the second valve in the schematic associated with the operation of actuator #1.
Circuit 1
In the first scenario, a component comes down a line (conveyor) and stops at a workstation.
A worker attaches a part to the component and presses a push-button to eject it off the line.
Assemble the circuit using the following equipment list:
3/2-way push-button valve, normally closed, spring return

Single-acting cylinder, spring return
With the valve, 3 refers to the number of connections, and 2 to the number of positions it can
take. Normally closed refers to its de-energized status (the box next to the spring), and is
opposite to electrical terminology in that normally closed means that no air can pass through
it.
WARNING: Make sure that the isolation switch is turned off before connecting or
disconnecting tubing, otherwise tubing will whip and may cause injury!
LAB 1
Once you have assembled the circuit, turn the isolation switch on and test the circuit. If it
works, proceed to lab 2. If it doesn’t, then you have an ideal opportunity to test your trouble-
shooting skills!
Circuit 2
In lab 2, a pneumatic actuator is use at a sorting station to open and close a gate to divert
defective components onto a branch conveyor. The gate is too heavy to use a single-acting
cylinder, and its position needs to be maintained after the switch is released.
Equipment list: 5/2-way valve with selector switch

Double-acting cylinder
LAB 2
Notice in labs 1 and 2 that the same air is used for both the operator’s input switch and the
actuator. If the actuator were large, and required a large flow of air to operate it quickly, the
input switch would also have to be large enough to accommodate the volume. If an air
conductor ruptured in the vicinity of the operator, there would be the potential for personal
injury. Lastly, if the operator were positioned some distance away from the sorting station,
the added length of large-diameter tubing would be expensive.
Circuit 3
In lab 3, we are going to simulate the operation of a large double-acting cylinder that must be
actuated from a push-button situated 100 feet away. Upon release of the push-button, the
cylinder must retract. We are going to isolate the input signal from the final control by use of
a piloted signal. This will allow smaller diameter tubing to be used to the remote operator’s
station, and if necessary, would also allow the use of a regulated lower air pressure signal
line for operator safety (similar to using a 120v switch and relay to start a 600v electric
motor).
Equipment list: 3/2-way push-button valve, normally closed, spring return

5/2-way single pilot valve, spring return
LAB 3
Circuit 4
In lab 4, we will use a valve with a cam follower (roller lever) that is actuated by a guard
being closed to provide operator safety. A double-acting cylinder operating a shear must
extend only when a guard is in place, and a push-button is activated. If the button is released,
or the guard is lifted, then the cylinder must retract.

3/2-way roller lever valve, normally closed, spring return
Dual-pressure valve
LAB 4
Notice that the dual-pressure valve requires two input signals in order to provide one output
signal (AND logic).
Circuit 5
Lab 5 is similar to the previous one, except that we wish to be able to operate this shear from
either of two controls, as well as ensuring that the safety interlock on the guard is always
operational. In order to accomplish this, we will also use a shuttle valve, which will transmit
one of two input signals (OR logic).
Equipment list: 2 - 3/2-way push-button valves, normally closed, spring return

Shuttle valve
Dual-pressure valve
LAB 5
Circuit 6
The previous circuits all required a continuous signal to operate them, either by holding the
push-button or using a détente. This is useful in many situations, for example where the
operator uses judgement in determining the operation or as a safety measure in that the
circuit deactivates immediately upon release of the button. However, it may be desirable to
have a circuit perform a series of functions with only one short impulse (i.e. push the button
and release). The circuit may need to operate until some other signal is received, then reset.
This is accomplished by means of a memory valve, also known as a bistable, double-piloted,
or impulse valve. Lab 6 is to be built using a memory valve to operate the cylinder. One
push-button will be required to extend the cylinder, and another push-button to retract the
cylinder.

5/2-way double pilot valve
LAB 6
Circuit 7
In circuit 7, a cylinder presses a bearing into a housing. It must actuate only when a push-
button is depressed and a safety gate is closed. The circuit must also incorporate an
alternative activation method, automatic return and speed control on both extension and
retraction strokes. The speed control must be effective no matter which way the load acts on
the cylinder.
The automatic return is provided by 1S4, which is tripped by the cam on the actuator piston
at the end of its extension stroke, and thus changes the position of the memory valve. Speed
control is effected by the use of flow control valves which meter the amount of air passing
through them. Notice that they meter the amount of air coming out of the cylinder, thus
providing a back pressure which will prevent a load from overrunning. Air travelling in the
opposite direction will bypass the flow control valve via the built-in check valve. This is
referred to as meter-out flow control.

2 - 3/2-way roller lever valves, normally closed, spring return
Shuttle valve
Dual-pressure valve
LAB 7
Circuit 8
Lab 8 features the use of a time-delay valve. This is a combination valve that incorporates
more than one individual component – in this case, a flow control valve, direction control
valve and an accumulator. The accumulator must fill up before pressure increases sufficiently
to overcome the spring and move the direction control valve. The flow control valve is
adjusted to vary the flow of air into the accumulator, and hence the amount of time before the
valve will act.
In lab 8, a vertically-mounted pneumatic cylinder provides a clamping force for an operation

that glues two components together. The cylinder must extend at a controlled speed until it
reaches full extension, remain at full extension for 5 seconds while the glue sets, and then
return as quickly as possible. The procedure is started by depressing a push-button, and will
not initiate unless a safety guard is closed, thus activating a roller lever. The cylinder is too
large for direct control.

Dual-pressure valve
Time delay valve
One-way flow control valve
LAB 8
Circuit 9
In lab 9, another combination valve called a pressure sequence valve is used. It consists of a
pressure control valve and a direction control valve. The pressure control valve will only
operate the direction control valve when it receives a pre-set signal.
A pneumatic cylinder is used to press a bearing into a seat. The cylinder is activated when a
roller switch on a safety gate is actuated, and a push-button is pressed. The cylinder will
continue to press until a pressure of 2 bar is reached, regardless of cylinder position. When 2
bar pressure is reached in the cylinder, the cylinder retracts. The cylinder extension speed
must be controlled.

Dual-pressure valve
Pressure sequence valve
One-way flow control valve
Pressure gauge
LAB 9
Circuit 10
In lab 10, a package must be raised from one conveyor to the level of another conveyor, and
pushed onto the second conveyor. When the package arrives at the elevator table, it will
trigger a push-button, which starts the sequence.
Cylinder 1 extends at a controlled rate, raising the package. Upon complete extension of
cylinder 1, cylinder 2 extends, also at a controlled rate, and pushes the package onto the
upper conveyor. After complete extension of cylinder 2, both cylinders are to retract
simultaneously at full speed. Confirmation that both cylinders have retracted is required
before the system will start again. The valves that provide the confirmation signals need to
be connected in series with each other.
DISPLACEMENT STEP DIAGRAM
When we incorporate more than one cylinder, it is helpful to draw a displacement step
diagram to show the sequence in which the cylinders extend and retract. Notice the use of
2S1 – an idle return roller lever valve. This valve should be positioned so that when cylinder
1 extends, it passes over the cam follower, activating it, but also allowing the signal to be
immediately cancelled. The idle return feature allows cylinder 1 to retract without re-
activating 2S1.
If we position the valve right at the end of the stroke, there is a possibility that the signal will
keep 2V1 permanently energized in the left-hand envelope, hence a signal to the other side of
2V1 would have no effect. This condition is known as signal overlap. If we use an ordinary
roller lever valve, we would get a second signal sent to 2V1 as cylinder 1 retracted.
3/2-way idle return roller lever valve, normally closed, spring return
Dual-pressure valve
2 - 5/2-way double pilot valves
2 - one-way flow control valves
2 - double-acting cylinders
LAB 10
Circuit 11
TRANSFER STATION
Lab 11 further demonstrates signal overlap by deliberately incorporating it into the following
circuit. Two cylinders are used to transfer parts from a magazine onto a chute. When a push-
button is pressed, cylinder 1 extends and pushes the part from the magazine onto a transfer
table. Cylinder 2 then pushes the part onto the out-feed chute. Cylinder 2 then retracts,
followed by cylinder 1. Notice that the sequence can not be re-activated until confirmation is
received that the two cylinders are fully retracted (1S2 and 1S3).

LAB 11
Notice that there are two signal overlap problems in this circuit. In the first step (see the
displacement step diagram), the double pilot valve 1V1 can receive signals from valves 1S1
and 1S2 at the same time, and hence will not change positions. The first of these signals
(1S2) will need to be cut short so that it is not active past its requirement in step 4.
The second overlap problem is with double pilot valve 2V2. In step 3, it receives a signal
from limit valve 2S1 when cylinder 1 (1A) has extended. This signal, which allows cylinder
2 (2A) to extend, is never cancelled. After 2A has extended, it trips limit valve 2S2, which in
turn sends a signal to 2V2 to reverse itself, and of course it cannot. Once again, the first
signal (2S1) needs to be cut short so that it is not active past its requirement in step 3.
Circuit 12
This circuit is the same as lab 11, except that the signal overlap is eliminated by replacing the
two roller lever valves 1S2 and 2S1 with idle return roller lever valves. These are not the
most accurate way of eliminating signal overlap, as they have to be positioned fairly
accurately to work properly, and may move with use.

2 - 3/2-way idle return roller lever valves, normally closed, spring return
LAB 12
Circuit 13
Lab 13 uses the same scenario as the previous two circuits, but adopts a more sophisticated
(and reliable) approach by using a single reversing valve. This valve (a double pilot valve
0V) ensures that a pressurized air signal is present at one side only of the memory valves
1V1 and 2V1 at any given time, and that the other side of the valves is always exhausted to
atmosphere.

LAB 13
Circuit 14
Once again we use the same scenario. Notice in the displacement step diagram that we have
reduced the number of steps by having the first cylinder retract as the second cylinder
extends. One very reliable way of achieving this is to use two reversing valves.
Once again there is the potential for two signal overlap conditions, one at each of the
memory valves 1V1 and 2V1. Both of the cylinders have to extend and immediately retract,
so the first signals to both 1V1 and 2V1 must be short in duration. This is accomplished by
using the two limit valves 1S3 and 2S2. These are activated by the cylinders after they have
extended, and send signals to the two reversing valves, which it turn cancel the first signal to
the memory valves 1V1 and 2V1 and send a signal to the opposite side.

LAB 14
Circuit 15
Finally, lab 15 is an example of a fully automated electro-pneumatic circuit. A component
arrives at a punching station and activates a photo sensor, which in turn initiates the
extension of a clamping cylinder. A second cylinder then extends and punches a hole in the
component and then retracts, followed by retraction of the first cylinder. The extension speed
of both cylinders must be controlled, but retraction must be as fast as possible. Confirmation
of retraction is required before the circuit can be re-activated. In order to provide automatic
control, magnetically actuated proximity switches are used for the first cylinder and roller
lever switches for the second cylinder. Relays, normally-open and normally-closed contacts
are used to transmit signals in the correct sequence and also to eliminate signal overlap.

Equipment list: 4 - 5/2-way double solenoid pilot valves
2 - double-acting cylinders with proximity switches
2 - roller lever switches
3 - relays
LAB 15 – ANSI
+
1A
-
+
2B
-
1A LS1 LS2 2B LS3 LS4
1V 2V
1A+ 1A- 2B+ 2B-
+24vdc 0vdc
LS1
CR1
Magnetic Proximity
1 Cylinder 1A
Retracted
LS2 CR2
Magnetic Proximity
2 Cylinder 1A
Extended
PB2
CR1 LS4 CR3
3 Start Cycle
CR3
4
CR3 1A+
5 Extend Cylinder 1A
CR2 2B+
6 Extend Cylinder 2B
CR3 2B-
7 Retract Cylinder 2B
LS3 1A-
8 Retract Cylinder 1A
LAB 15 – ISO
For convenience, the electrical schematic is shown in both ISO and ANSI configurations. A
logical progression from here would be to write a PLC program to operate the same circuit
and eliminate the relay logic.

Pneumatic Control and Automation

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Pneumatic Control and Automation

3/2-way push-button valve, normally closed, spring return

Equipment list: 5/2-way valve with selector switch

Equipment list: 3/2-way push-button valve, normally closed, spring return

Equipment list: 3/2-way push-button valve, normally closed, spring return

Equipment list: 2 - 3/2-way push-button valves, normally closed, spring return

Equipment list: 2 - 3/2-way push-button valves, normally closed, spring return

Equipment list: 2 - 3/2-way push-button valves, normally closed, spring return

In lab 8, a vertically-mounted pneumatic cylinder provides a clamping force for an operation

Equipment list: 3/2-way push-button valve, normally closed, spring return

Equipment list: 3/2-way push-button valve, normally closed, spring return

DISPLACEMENT STEP DIAGRAM

DISPLACEMENT STEP DIAGRAM

Equipment list: 3/2-way push-button valve, normally closed, spring return

Equipment list: 3/2-way push-button valve, normally closed, spring return

DISPLACEMENT STEP DIAGRAM

Equipment list: 3/2-way push-button valve, normally closed, spring return

DISPLACEMENT STEP DIAGRAM

1A LS1 LS2 2B LS3 LS4

1A+ 1A- 2B+ 2B-

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