Pneumatic ElectroPnuematic Jan2008
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Transcript of Pneumatic ElectroPnuematic Jan2008
2008 1
PNEUMATICS AND ELECTRO-PNEUMATICS TECHNOLOGY
UNIVERSITY KUALA LUMPURMALAYSIA FRANCE INSTITUTE
2008 2
Principles of pneumatics
Pnuematics defined • Pnuema – Air (wind or breath in ancient Greek)
• Matic – movement
• It means control movement of air• In industries, it is referred as the used of compressed air to transmit power or/and motion
2008 3
Principles of pneumatics
MOST ENERGY SOURCE
• Electricity• Hydraulics• Pneumatic• Etc
2008 4
Principles of pneumatics
Why Pnuematic? The advantages:• Cheap – Air is available in unlimited
supply• Air is non-explosive and non-toxic• Compressed air can be transmitted over
long distance• Compressed air can be stored• Fast• Easily control the speed and movement• Clean• Overload proof
2008 5
Principles of pneumatics
Disadvantages:• Air absorbs moisture and drying may
have to be considered• The exhaust air causes noise. Sound
absorbers may be required• Pressure limit which can be used in a
compressed air system• Smooth and even movement not
possible
2008 6
Principles of pneumatics
Pneumatics is used in carrying out machining and working operations.For example:• Drilling• Turning• Milling• Sawing• Finishing• Forming• Quality control
2008 7
Principles of pneumaticsApplication example: Conveyor line diverter
2008 8
Principles of pneumatics
Application example: Pneumatic cutter
2008 9
Principles of pneumatics
Unit for pressure• PSI• Pa• Bar (normally used in industries)• N/m2 (SI unit)
- Gauge pressure vs absolute pressure
- Vacum
2008 10
Principles of pneumatics
ELEMENTS OF PNUEMATICS SYSTEM• Energy supply, source• Input elements, input signal• Processing elements, processor
signal• Final control element, control signal• Actuating devices, output
2008 11
Principles of pneumatics
2008 12
Principles of pneumatics
2008 13
Electro-pneumatic System• Combination of electrical control and
pneumatic technologies
2008 14
Electro-pneumatic System
2008 15
Electro-pneumatic SystemAdvantages of electro-pneumatic:• Higher reliability (fewer moving parts
subject to wear)• Lower planning and commissioning
effort particularly for complex controls• Lower installation effort, particularly
when modern components such as valve terminal are used
• Simpler exchange of information between several controllers
2008 16
Pnuematic System and Air Generation
ENERGY SUPPLY UNIT (AIR GENERATION)
• Air compressor• Air receiver/reservoir• Air cooler• Air dryer• Service unit – Filter, Regulator &
Lubricator (FRL unit)
2008 17
Pnuematic System and Air GenerationCompressed air distribution system:
2008 18
SYMBOL FOR ENERGY SUPPLY UNIT
2008 19
SYMBOL FOR ENERGY SUPPLY UNIT
2008 20
Energy Supply Unit
TYPE OF COMPRESSOR• Reciprocating
- piston- diaphragm
• Rotary- vane- screw
• Flow compressor- axial flow- radial flow
2008 21
Energy Supply UnitType of compressor
2008 22
ENERGY SUPPLY UNIT
Type of compressor
2008 23
Type Of Compressor
2008 24
Type Of Compressor
2008 25
Air Drying
Refrigeration Drying
2008 26
Refrigeration Drying
2008 27
AIR DRYING
Absorption and Adsorption drying
2008 28
ABSORPTION DRYING
2008 29
ADSORPTION DRYING
2008 30
ENERGY SUPPLY UNITSURVICE UNIT• Compressed air filter
2008 31
COMPRESSED AIR FILTER
2008 32
SERVICE UNIT
Pressure regulating valve
2008 33
PRESSURE REGULATING VALVE
2008 34
SERVICE UNITCompressed air lubricator
2008 35
COMPRESSED AIR LUBRICATOR
2008 36
Pneumatic Symbols and Standard
Flow path
Switching position
Flow path blocked
Connection ports
Directional Control Valves
2008 37
- Way valve
Number of ports
Number of switching positions
2 2
- Way valve32
Pneumatic Symbols and Standard
2008 38
Pneumatic Symbols and Standard
Directional control valves
2008 39
Pneumatic Symbols and Standard
Port designation
2008 40
Port designation
2008 41
Input Elements ValveTypes of actuation
2008 42
Input Elements ValveTypes of actuation
2008 43
Pneumatic Symbols and StandardNon-return, flow control and pressure control valves
2008 44
Pneumatic Symbols and StandardNon-return, flow control and pressure control valves
2008 45
Pneumatic Working Elements
Linear:• Single acting cylinder• Double acting cylinder• Rodless cylinder
Rotary:• Rotary actuator• Swivel drive/cylinder
2008 46
Pneumatic Working Element
Single acting cylinder
2008 47
Single Acting Cylinder
2008 48
Single Acting Cylinder
Bellow / membrane cylinder
2008 49
Pneumatic Working ElementDouble acting cylinder
2008 50
Double Acting Cylinder
• With out cushioning
• With cushion
2008 51
Cylinder Construction
2008 52
Type Of Mounting
2008 53
Type Of Mounting
2008 54
Type Of Mounting
2008 55
Type Of Mounting
Rod end mountings
F
UF
2008 56
Rodless Cylinder
2008 57
Rodless Cylinder
2008 58
Rotary Cylinder & Swivel Drive
Swivel Drive
2008 59
Rotary Cylinder & Swivel Drive
Rotary cylinder
2008 60
Force CalculationPascal’s Law:pressure exists when a force F is imposed on an enclosed fluid with a surface A, The pressure exerts an equal effect on all points of the surfaces.
FP
A
P =FA
N/m2
2008 61
Force CalculationTheoretical Force: Fth
Fth is the calculated force based on Pascal’s Law without consideration of all the resistance forces.
Frictional Resistance: Ff
To be considered during extend and retract strokes. Estimated at about 10 to 12% of Fth.
Spring Resistance: Fsp
To be considered when using spring loaded single acting cylinders. Estimated at about 15% of Fth.
2008 62
Force Calculation
Example 1:A double acting cylinder is used to transfer work-pieces in a production machine. Determine the extend and retract forces if the piston diameter of the cylinder is 80mm, rod diameter 15mm and the pressure used is 6bar. Assume frictional force is 10% of theoretical force.
2008 63
Force Calculation
Example 2:A clamping vice uses a single acting cylinder to clamp the work-pieces. Determine the extend force if the piston diameter of the cylinder is 80mm, rod diameter 15mm and the pressure used is 6bar. Assume frictional and spring forces are 10% and 15% of theoretical force respectively.
2008 64
Design and construction of pneumatic control circuits
Exercise 1.
2008 65
Design and construction of pneumatic control circuits
Exercise 2.
2008 66
Design and construction of pneumatic control circuits
Components designation
2008 67
Design and construction of pneumatic control circuits
Components designation: Example
2008 68
Design and construction of pneumatic control circuits
Direct and indirect actuation
2008 69
DIRECT ACTUATION
2008 70
INDIRECT ACTUATION
2008 71
Pneumatic Control DevicesDirectional Control Valves
2008 72
Directional Control Valves
2008 73
Directional Control Valves
2008 74
Directional Control Valves
2008 75
Directional Control Valves
2008 76
Directional Control Valves
2008 77
Directional Control Valves
2008 78
Directional Control Valves
2008 79
Directional Control Valves
2008 80
Pneumatic Control DevicesShuttle Valve (OR)
2008 81
Shuttle Valve (OR)
2008 82
Pneumatic Control DevicesDual Pressure Valve (AND)
2008 83
Dual Pressure Valve (AND)
2008 84
Design and construction of pneumatic control circuits
EXERCISE 3.
2008 85
SHUTTLE VALVE (OR FUNCTION)
2008 86
Design and construction of pneumatic control circuits
EXERCISE 4.
2008 87
DUAL PRESSURE VALVE (AND FUNCTION)
2008 88
Pneumatic Control DevicesOne-way Flow Control Valve
2008 89
One-way Flow Control Valve
2008 90
One-way Flow Control Valve
2008 91
Design and construction of pneumatic control circuits
EXERCISE 5.
2008 92
5/2 WAY DOUBLE PILOT VALVE (SPEED CONTROL)
2008 93
Design and construction of pneumatic control circuits
Exercise 6. A container of washers is to be dipped in and out of the cleaning bath by using a double acting cylinder. The start and stop for this continuous movement is to be achieved by actuating the ‘START’ and ‘STOP’ pushbuttons each.On actuating the ‘STOP’ pushbutton, the container should stop at the top. The speed for forward and retract strokes are controllable.
2008 94
ELECTRO PNEUMATIC
Pneumatic Vs electro-pneumatic Electro-pneumatic component Electrical component Electro-pneumatic controller Design and construction of electro-
pneumatic control circuits
2008 95
Electro-pneumatic components
Function of solenoid A magnetic field is
induced when a current passed through an electrical conductor
A soft iron core (amature) is drawn into a coil through which the current is flowing
2008 96
Electro-pneumatic componentsSolenoid Valves
2008 97
Solenoid Valves
2008 98
Solenoid Valves
2008 99
Solenoid Valves
2008 100
Solenoid Valves
2008 101
Solenoid Valves
2008 102
Solenoid Valves
2008 103
Electrical components
2008 104
Electrical components
2008 105
Electrical components
2008 106
Electrical components
2008 107
Design and construction of elctro-pneumatic control circuits
Using a sorting device, parts are to be transferred from conveyor belt. By pressing the pushbutton switch, the piston rod of a single-acting cylinder pushes the part off the conveyor belt. When the pushbutton is released, the piston rod returns to the retracted end position.
Exercise 7:
2008 108
Design and construction of electro-pneumatic control circuits
Using a special device, the valve in a pipe line is to be opened and closed. The valve is opened by pressing the pushbutton switch. When the pushbutton is released the valve is closed.
Exercise 8:
2008 109
Design and construction of electro-pneumatic control circuits
Wooden planks are to be pushed along from a gravity feed magazine to a clamping device. By pressing a pushbutton switch one plank is pushed by the slide out of the gravity feed magazine. After the slide has reached the forward end position it is returned to its start position.
Exercise 9:
2008 110
Electrical components
2008 111
Design and construction of electro-pneumatic control circuits Exercise 10:
Using a conveyor belt, parts are to be transported in linear timed sequence to work stations which are arranged in line after one another. When the latching pushbutton (or selector) switch is activated the main wheel is indexed by the oscillating piston rod of a cylinder via a pawl. When the pushbutton (or selector) switch is activated again the drive is switched off.
2008 112
Electrical components
Coil
Coil connections
Contacts
Contact connections
Return spring
Cover
Symbol
A1
A2 11
12
14
21
22
24
Armature
Relay
2008 113
Relay
Symbol
A1
A2 11
1214
21
2224
A1 A2 4 2 1
2008 114
Relay
Symbol
A1
A2
11
1214
21
2224
A1 A2 4 2 1
2008 115
Design and construction of electro-pneumatic control circuits
Repeat the exercise 10 but the conveyor is controlled by using ‘Start’ and ‘Stop’ pushbuttons.
Exercise 11:
2008 116
Electro-pneumatic controller
2008 117
Electro-pneumatic controller
2008 118
Electro-pneumatic controller
2008 119
Electro-pneumatic controller
2008 120
Electro-pneumatic controller
2008 121
Electro-pneumatic controller
2008 122
Electro-pneumatic controller
2008 123
Electro-pneumatic componentsPressure Switch
2008 124
Design and construction of electro-pneumatic control circuits
Exercise 12:
Parts are to be stamped with a stamping device. By pressing two pushbutton switches the die is pushed down and the part is stamped. When the stamping pressure has been achieved the dieis returned to its start position.
2008 125
Electrical componentsTime relay (Timer)
Two types:•Pull-in (on) delay and •Drop-out (off) delay
Pull-in (on) delay
2008 126
Pull-in (on) delay Timer
Signal behavior:
Time relay (Timer)
2008 127
Drop-out (off) delay
Time relay (Timer)
2008 128
Time relay (Timer)Drop-out (off) delay
Signal behavior:
2008 129
Design and construction of electro-pneumatic control circuits
Using a hot pressing die, packing material is to be sealed by application of heat. By pressing a pushbutton switch the heating rail is advanced and the packaging material is heated along the adhesive strip. After the adhesion time of 10 seconds has reached, the heating rail is returned to its start position.
Exercise 13:
2008 130
Design and construction of electro-pneumatic control circuits
Using a transfer station blocks are to be transferred from a magazine to a processing station.The blocks are pushed out of the magazine by cylinder 1A and transferred to the processing station by cylinder 2A. The piston rod of cylinder 2A may only return when the piston rod of cylinder 1A has reached the retracted end position. The magazine is monitored by means of a limit switch. If there are no more blocks in the magazine, it is not possible to start the cycle. This is indicated by means of an audible signal. The control is to be operated in single cycle.
Exercise 14:
2008 131
Control of Multiple Cylinders
Chronological sequence is simplified by using:• Displacement step diagram (pictorial)• Vector diagram
Example: 1A→ 2A→ 2A← 1A←• Abbreviation notation
Example: 1A+ 2A+ 2A- 1A-
2008 132
Design and construction of electro-pneumatic control circuits
Workpieces are inserted into the clamping device by hand. Clamping cylinder 1A is to extend when the start button is pressed. When the workpiece is clamped, it is to be drilled via feed unit 2A and the drill retracted once again. Then, the clamping cylinder 1A is to release the workpiece.
Exercise 15:
2008 133
Design and construction of electro-pneumatic control circuits
2008 134
Control of Multiple CylindersMethods for construction a circuit diagramTwo primary methods:
• Intuitive method - conventional or trial and error methods.
• Methodical design I accordance with prescribed rules and instructions.
Signal overlapsOvercome by signal cut-out through:1) Components
• Idle roller limit switch• Timer
2) Circuit• Electrical Cascading Circuit• Electrical Shift register
2008 135
THE ENDTHANK YOU