Industrial Electronics

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ELECTRO PNEUMATIC
SYSTEM

Chapter 3

Intro of Electro-pneumatic system

Pneumatic products represent a multi-billion dollar
industry today.
Pneumatic devices are used in many industrial
applications.
Most pneumatic devices are designed to use clean dry
air as an energy source.
The actuator then converts that compressed air into
mechanical motion. The type of motion produced
depends on the design of the actuator.
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Into of electro-pneumatic system

-Electro
-Electro pneumatic
pneumatic system
system consist
consist of
of both
both
electrical
electrical and
and pneumatic
pneumatic system.
system.
-Usage
-Usage of
of electro
electro pneumatic
pneumatic includes:
includes:
1)
1) Packaging
Packaging
2)
2) Stamping,
Stamping, shearing
shearing && embossing
embossing part
part
3)
3) Sorting
Sorting part
part
4)
4) Component
Component stacking
stacking
5)
5) Material
Material stacking
stacking
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Example of pneumatic
connections/diagram:

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Example of electrical wiring/connection

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Solenoid symbol which moves the valve.

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Directional Control Valve: Port & Position

-directional
-directional control
control valve
valve is
is attach
attach with
with
solenoid,
solenoid, so
so that
that itit can
can move
move forward
forward &&
backwards.
backwards.
-the
-the movement
movement of
of the
the valve
valve is
is allow
allow
compressed
compressed air
air go
go into
into the
the airway
airway of
of the
the
valve
valve to
to control
control the
the movement
movement of
of the
the
cylinder.
cylinder.
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Directional Control Valve: Port &

Position..cont
i) Valve switching positions are represented by squares

ii) The number of switching positions of the valve is

shown by the number of squares
iii) Lines indicates arrow show the direction of flow
paths
iv) Shut off positions are identified in the boxes by lines
at right angles
v) The connection (inlet and outlet ports) are
shown by lines on the outside of the box and
are drawn in the initial position.
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Several type of valve

Port or

DIN ISO
5599

Lettering
System

Pressure port

Exhaust port

Exhaust ports

5,3

R,S

Signal
outputs

2,4

B,A

connection

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Numbering system for pneumatic circuit

element
0.1
Air
0.1
Airsupply
supplyunit
unit
1.0,
Working
1.0,2.0
2.0etc
etc
Workingelement
element(cylinder)
(cylinder)
1.1,2.1
Control
1.1,2.1etc
etc
ControlElement
Element(solenoid)
(solenoid)
1.01,1.02
1.01,1.02etc
etc Element
Elementbtwn
btwncontrol
controlelement
element &&working
workingelementelementone
oneway
wayflow
flowcontrol
controlvalve
valve

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Control of single acting cylinder

-rest
-restposition,
position,air
airsupply
supplyshut
shutoff,
off,
cylinder
cylinderretracted
retractedby
bythe
thespring.
spring.
-when
-whenswitch
switchclosed,
closed,current
currentflow
flow
to
tothe
thecircuit
circuit&&start
startto
toenergize
energize
solenoid
solenoidcoil
coil
-Magnetic
-Magneticfield
fieldcreated,
created,push
pushthe
the
plunger
plungerthat
thatwill
willslide
slidethe
thevalve
valveto
to
the
theright.
right.
-This
-Thiswill
willallow
allowthe
theair
airto
toflow
flow
inside
inside
the
thepiston
piston&&extend
extendthe
thepiston.
piston.
-If
-Ifswitch
switchreleased,
released,the
thevalve
valvewill
will
slide
slideback
back&&cause
causethe
theair
airto
tostop.
stop.
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Control of double acting cylinder

-rest
-restposition,
position,air
airsupply
supplyflowing
flowingto
to
the
thecylinder
cylinderpiston
pistonrod
rodvia
viathe
the
-rest
[ pushing
valve
valveand
and
pushingthe
thepiston
pistonat
at
rest/retraction
rest/retractionposition-no
position-nocurrent
current
flow
flowto
tothe
thesolenoid
solenoid
-switch
-switchclosed,
closed,energized
energizedsolenoid
solenoid
coil-magnetic
coil-magneticfield
fielddevelop
developat
at
solenoid.
solenoid.
-magnetic
-magneticfiled
fileddevelop
developpush
pushthe
the
plunger
plungerand
andcause
causevalve
valveslide
slideto
to
the
theright.
right.
-this
-thisallow
allowair
airflow
flowinside
insidethe
thepiston
piston
via
viathe
theother
otherport
port&&push/extend
push/extend
the
thevalve.
valve.
-when
-whenswitch
switchreleased,
released,current
currentnot
not
flow,
flow,cause
causethe
themagnetic
magneticfield
fieldweaker
weaker
and
andvanish-valve
vanish-valveslide
slideto
toinitial
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position.
position.

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Basic circuit for electro pneumatic circuit

1) AND

2) OR

3) NOT

5) Dominant
reset

4) Memory
latching

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Cont..
6) Dominant set

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Process Sequence Description

There are several method to describe
process sequence:
1) Simple narative
2) Boolean
3) Grafset
4) Motion diagram
5) Displacement diagram
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Simple narrative
A push button is used to turn on the conveyor belt
A that brings the bottles to the filing line. Sensor 1
that is placed at the center of the conveyor A will
stop the conveyor belt A upon detecting the bottle
and open the valve for filing for 2 second. After
that the conveyor belt will be on again until the bottle is
sensed by sensor 2 at the end of conveyor belt A.
Conveyor belt A once again stop and the solenoid is
energized for 3 seconds in order for the piston to push the
bottle to conveyor belt B. The process repeats until stop
button is pressed.
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cont..
1st: please identify input and output
Input: PB,Sensor 1,timer 1 contact(2
sec),sensor 2,timer 2 contact(3
sec)
Output:Conveyor A,valve,timer 1
coil(2 sec), solenoid,timer 2
coil(3 sec)
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Cont.
2nd: Please simplified the narrative statement
1)
2)
3)
4)
5)
6)

PB turns on conveyor A
Sensor1 stop conveyor A,open valve,timer 1 on for 2
sec
After timer 1 times up(after 2 sec),conveyor A on.
Sensor 2 stops the conveyor,energize solenoid,timer 2
on for 3 sec.
Timer 2 times up(after 3 sec),conveyor A on again.
Stop button reset all

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Boolean
1) Another one method to describe process
sequence.
2) Is a logic expression using gates.

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cont
Example:
The door of the automatic train will be locked if start button is
pushed and will unlocked when sensor 1 detects its arrival at
station 1. Sensor 2 that is placed at the entrance door of the train
will count the number of train passengers on that day.

D= door ; D = lock , D = unlock

S1 = sensor 1 ; S1 = sense , S1 = not sense
S2 = sensor 2 ; S2 = sense , S2= not sense
SB = start button ; SB = pressed ,SB = not pressed
CNT = counter ;RB=reset button ;RB=reset, RB=not reset
Boolean:
1. D = SB.S1
D=SB.S1
2. CNT = S2.S1.RB
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Grafset
Example:
The tank system has the narrative
description below:
Fill the tank to level A from valve A
Fill the tank to level B from valve B
Start a timer, heater and stirrer for 5
minutes.
Open output valve C until the empty
switch engages.

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Cont.
I/O assignment:
input
LA - level A
LB - Level B
ES empty switch
TIM timer contact(5 mins)
- times up after 5 min.

output
VA valve A
VB valve B
VC valve C
TIM timer coil(5 min)
- timer on for 5 min.

SB - start button

H heater
ST - stirrer

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cont

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Motion Diagram
1) The input and the output are separated
with the input at the upper side and the
output is at the bottom side.

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Displacement Diagram
1) Presented in form of graph indicates the
position of the cylinders and the
displacement

Step 1 : Cyl1 and Cyl 2 extend

Step 2 : Cyl 1 retracts while Cyl 2 remains
extend for 3 seconds.
Step 3 : Cyl 1 remains retracts for 3 seconds
and Cyl 2 retracts
Step 4 - step 6 : The position of Cyl 1 and Cyl 2
similar as Step 1 Step 3
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Con.

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Single Acting Cylinder

(a) Spring Retracted Type: A spring
retracted single acting cylinder develops
thrust in one direction only. The piston
rod is returned by the spring

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Contd
1- Piston
2- Piston rod
3- Return Spring
4- Rod Cover
5- Head Cover
6- Piston Seal
7- Stopper Spring
8- Guiding Ring
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Contd
When compressed air is supplied to the
air port, the compressed air will act on
the piston extending the piston rod

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Contd
When the compressed air is allowed to
vent out of the air port, the spring force will
retract the piston rod

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Single Acting Cylinder

(b) Spring Extended Type: A spring
extended single acting cylinder develops
thrust in one direction only. The piston
rod is extended by the spring

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Contd
1- Piston
2- Piston rod
3- Return Spring
4- Rod Cover
5- Head Cover
6- Piston Seal
7- Stopper Spring
8- Guiding Ring
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Contd
When compressed air is supplied to the
air port, the compressed air will act on the
piston retracting the piston rod

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Contd
When the compressed air is allowed to
vent out of the air port, the spring force will
extend the piston rod

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Double Acting Cylinder

A double acting cylinder develops thrust in
both extending and retracting directions as
air pressure is applied alternately to
opposite sides of a piston

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Contd
1- Piston
2- Piston Rod
3- Rod Cover
4- Head Cover
5- Piston Seal
6- Rod Seal

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Contd
The piston rod is pushed out when
compressed air goes in the inlet of the
head cover.
If the compressed air goes in the inlet of
the rod cover and the air in the inlet of the
head cover is exhausted, the piston rod is
pushed back to its original position

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VALVES
A directional control valve determines the
flow of air between its ports by opening,
closing or changing its internal
connections

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2/2 Valve
To drive air motors and pneumatic tools

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3/2 Normally Closed Valve

Used to drive single acting cylinders or act
as an on/off switch

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3/2 Normally Open Valve

Used to drive single acting cylinders

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4/2 Valves
To drive double acting cylinders, with a
common exhaust

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5/2 Valves
To drive double acting cylinders with
individual exhaust

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5/3 Exhaust Center

To drive double acting cylinders with the
possibility of stopping the cylinder in any
position

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5/3 Closed Center

To drive double acting cylinders with the
possibility of stopping the cylinder in any
position

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5/3 Pressure Center

Used to drive double acting, through rod
cylinder with the possibility of stopping the
cylinder in any position

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Example 1
The opening and closing the door (similar to bus door) is controlled by
using single acting cylinder. The opening of the door is activated by
using push button switch PB1. Means, when PB1 is pressed, the door is
open (Cylinder start to extend). LS1 will detect the full extension of
cylinder. (Door is fully open). The door remains open for 10 sec before it
is automatically closed.
Note: Use 3/2 way valve normally close.
Assume traveling time for cylinder from original
position to full extension (or
vice versa) is 1 sec.

1)
2)
3)
4)
5)

Please list out input and output.

Please draw grafset
Please draw motion diagram
Please draw displacement diagram.
Please draw pneumatic and circuit diagram
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Example 2
The opening and closing the door (similar to bus door) is controlled by
using double acting cylinder. The opening of the door is activated by
using push button switch PB1. Means, when PB1 is pressed, the door is
open (Cylinder start to extend). LS1 will detect the full extension of
cylinder. (Door is fully open). The door remains open for 10 sec before it
is automatically closed.
Note: Use 5/2 way directional valve.
Assume traveling time for cylinder from original position to full
extension (or vice versa) is 1 sec.

1)
2)
3)
4)
5)

Please list out input and output.

Please draw grafset
Please draw motion diagram
Please draw displacement diagram.
Please draw pneumatic and circuit diagram
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Exercise 1
A single acting cylinder will extend when
push button(PB) is pressed and will retract
when PB is released.
(i. Assume travelling time for single acting cylinder to move
from initial position to full extension/full retraction is 2 sec
ii. Use 3/2 valve NC)
1)
2)
3)
4)
5)

Please list out input and output.

Please draw grafset
Please draw motion diagram
Please draw displacement diagram.
Please draw pneumatic and circuit diagram

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Exercise 2
A single acting cylinder will extend when
push button(PB) is pressed and will
retract when the extension position is
detected by Limit switch 1(LS1)
(Assume travelling time for single acting cylinder to move
from initial position to full extension/full retraction is 2 sec)
1)
2)
3)
4)
5)

Please list out input and output.

Please draw grafset
Please draw motion diagram
Please draw displacement diagram.
Please draw pneumatic and circuit diagram
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Exercise 2-1
A single acting cylinder will extend when
push button(PB) is pressed and will start to
retract when it reach full extension position.
(Assume travelling time for single acting cylinder to move
from initial position to full extension/full retraction is 2 sec)
1)
2)
3)
4)
5)

Please list out input and output.

Please draw grafset
Please draw motion diagram
Please draw displacement diagram.
Please draw pneumatic and circuit diagram
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Exercise 3
A single acting cylinder will extend when
push button (PB) is pressed. A lamp
will on when the piston has extended 15mm
from the initial position (detected by limit
switch 1(LS1)). The piston will retract to its
initial position and the lamp will off after 4
second.
(Assume travelling time for single acting cylinder to move
from initial position to full extension/full retraction is 2 sec)
1)
2)
3)
4)
5)

Please list out input and output.

Please draw grafset
Please draw motion diagram
Please draw displacement diagram.
Please draw pneumatic and circuit diagram
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Exercise 4
PB will cause cyl. 1 extend until LS1 detect
which cause cyl. 2 extends too.LS2 at the
end of cyl. 2 will cause timer to activate for
10 sec. After 10 sec the lamp will on and at
the same time cyl. 1 and cyl. 2 will retract
It use single acting cyl. & 3/2 way NC valve.
(Assume travelling time for cyl 1 and cyl 2 from it full
retract to it full extend or vice versa is 1 sec)
1)
2)
3)
4)
5)

Please list out input and output.

Please draw grafset
Please draw motion diagram
Please draw displacement diagram.Need to mention the exact
time it need to extend and retract.
Please draw pneumatic and circuit diagram
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Exercise 4-1
PB will cause cyl. 1 extend until LS1 detect
which cause cyl. 2 extends too. At it full extension,
it will cause timer to activate for
10 sec. After 10 sec the lamp will on and at
the same time cyl. 1 and cyl. 2 will retract
It use double acting cyl. & 5/2 way valve.
(Assume travelling time for cyl 1 and cyl 2 from it full
retract to it full extend or vice versa is 1 sec)
1)
2)
3)
4)
5)

Please list out input and output.

Please draw grafset
Please draw motion diagram
Please draw displacement diagram.Need to mention the exact
time it need to extend and retract.
Please draw pneumatic and circuit diagram
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6. When PB is pressed, after 5 sec cylinder A will extend. At it full

extension, cylinder A will hit LS1 and caused timer to activate for 5
second before cylinder B start to activate. LS2 will detect the full
extension of cylinder B and remain at it full extension for 5 second
before cylinder A and B retract. When cylinder A at it full retraction, it
will hit LS3 which cause lamp to activate for 2 second.
Note: Cylinder A and B use single acting cylinder.
Use 3/2 ways valve normally close.
Assume traveling time for cylinder A and B from its origin to
full extension or vice versa is 2 second.
1. Draw grafset and motion diagram.
2. List out input and output.
3. Draw displacement diagram.
4. Draw pneumatic and circuit diagram.

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7. In order to drill piece of wooden block, we need to use double

acting cylinder A, B and C (5/2 way valve). When PB is pressed,
cylinder A will push the wooden block until wooden block is detected
by LS2 which cause cylinder C extend to hold the wooden block
from move. When cylinder C at it full extension, cylinder B will
extend. When LS3 detect the full extension of cylinder B, it will start
doing drilling process for 10 sec. When finished drilled (after 10
sec), cylinder B will retract. When cylinder B is fully retract, cylinder
A and cylinder C will start to retract.
(Note:
: Assume traveling time for cylinder A, B, C from origin state to
full retraction/full extension is 2 second)
: Solenoid for valve A (cylinder A)-Y1 and Y2
: Solenoid for valve B (cylinder B) -Y3 and Y4
: Solenoid for valve C (cylinder C) -Y5 and Y6

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Cartesian Robot as shown above is used to transfer Load from point A

to point C.
It uses 3 different cylinders:
Double Acting Cylinder (5/2 way valve) : Move down (activate Y1) and up robot
hand (activate Y2).
Single Acting Cylinder (3/2 way valve NC): Grip (activate Y3) and ungrip the load.
Single Acting Cylinder (3/2 way valve NC): Move right (active Y4) and left
robot hands.
When PB is pressed, the robot hand move downwards until it detect by down
sensor. Then, the gripper start to grip the Load until it is detected by grip sensor.
After that, robot hand move upwards until it is detected by up sensor. Then, it move
towards right until it reach the most right position as shown in Figure 2 above.
After that, the robot hand move downward until it detect by down sensor. Then, the
gripper start to ungrip (release) the load until it detect by ungrip sensor. Then, it
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move upwards until it detect by up sensor. Finally, the robot hand will moves to its
original position (most left position).

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Assume:
Time for cylinder to move from up to down (or vice versa) is 2 sec.
Time for cylinder to grip/ungrip the Load is 0.5 sec.
Time for cylinder to move from right to left (vice versa) is 5 sec.
Next action will not be executed unless previous action is executed
first.
1) Draw pneumatic diagram(de-energize & energize state
for DOUBLE ACTING CYLINDER only)
2) Draw a motion diagram
3) Draw displacement diagram(Cylinder A,B and C)
Please include all traveling time in your diagram
4) Draw electric diagram
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