basic pneumatic training

8/17/2019 Basic Pneumatic Training

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BASICS OF PNEUMATICS



Composition of air

• Air is composed

mainly of nitrogen

and oxygen

Composition by Volume

Nitrogen 78.09% N2

Oxygen 20.95% O2

rgon 0.9!% r Ot"ers 0.0!%



#ressure

• $ bar $00000

N&m2 'Ne(tons

per s)uare metre*

• $ bar $0 N&+m2

Pressure is defined as

force acting per unit

area

For measuring lower

pressures the millibar

(mbar) is used 1000 mbar = 1 bar

For measurements in

pounds per square

inch (psi)1 psi = !"#$mbar

1%"$ psi = 1bar



Compresse, air• &hen we are applying

force to the normal air' itwill get compressed

• ormally in industrial

application the range of

pressure will be 10bar

• For special application

li*e testing and in

submarine applicationhigh pressure is used.

+ow

range

,ypical-ndustrial

range

0

1

.

/%

$

!

#10

11

1.

1/

1%

1$

11

0

1

./

%

$

!

#

10

11

1.

1/

1%

1$1

b s o l u t e p r e s s u

r e b a r a

- a u g e p r e s s u r e

b a r g

ull /a+uum

tmosp"ere

xtended

-ndustrial

range



#ressure units

• ,here are many units of pressure measurement"

2ome of these and their equi3alents are listed

below"

• 1 bar = 100000 4m.• 1 bar = 100 *Pa

• 1 bar = 1%"$0 psi

• 1 bar = 101# *gf4m.

• 1 mm 5g = 1"//% mbar approx"

• 1 mm 5.6 = 0"0## mbar approx"

• 1 ,orr = 1mm5g abs (for 3acuum)

7ore units of pressure



lo( units

• lo( is measure, as a /olume

of free air per unit of time• #opular units are

1 +itres or cubic decimetres persecondl/s or dm3 /s

1 8ubic metres per minutem3 /m

1 2tandard cubic feet perminute (same as cubic feet offree air) scfm

• 1 m/ 4m = /$"/1 scfm

• 1 dm/ 4s = ."1 scfm

• 1 scfm = 0"%. l4s• 1 scfm = 0"0.!/ m/ 4min

1 cubic metre

or 1000 dm/

1 litre or

cubic decimetre

1 cubic foot



ree air flo(

Actual 3olume of 1 litreof free air at pressure

• ,he space between the bars

represents the actual 3olume

in the pipe occupied by 1 litre

of free air at the respecti3e

absolute pressures"

• Flow ta*es place as the result

of a pressure differential' at1bar absolute (0 bar gauge)

there will be flow only to a

3acuum pressure

• -f the 3elocity were the same

each case will flow twice theone abo3e

0

1 4!

1 41

1 4%

1 4.

1 litre

1bar a

.bar a

%bar a

!bar a

1bar a



CO#3446 3

• 4N :4 3 34C4 :4

#34;34 O34 :4N

:O#43C #34;34'$ <3* :

C==46 CO#3446 3.



##=C:ON O CO#3446 3

• NN- N6 CON:3;C:ON N6;:3>.

• <O::=N- N6;:3>.

• 3O==N- == ? O;N634.

• ;:OO:V4 N6;:34.• N6;:3= ;:O:ON.

• CN4 :OO=.

• N6 :OO=.

• O:43.



:>#4 O CO#34O3

CO#34O3

#O:V4 6#=C44N: 6>NC

C4N:3;-=34C#3OC:N- 3O:3>:N =O<4C34 @=



RECIPROCATING

COMPRESSOR



As the piston descends,increasing the available

space, the decrease in

pressure causes the

inlet valve to open and

air to be drawn into thecompressor chamber.

Subsequently, after thepiston has passed its

turning point

corresponding to the

maximum volume of the

compressor chamber, theinlet valve closes as the

air pressure starts toincrease.

As the volume of thecompression chamber

decreases, the air

pressure increases.

Finally, when thepressure has reached a

pre-determined value,

the discharge valve

opens, and the

compressed air leave thecompression chamber.



98-P968A,-: A-9 867P9226998-P968A,-: A-9 867P92269

• 98-P968A,-: 867P92269 862-2, 6F F6++6&-: 7A- PA9,2

1"76,69 %"P-2,6" "-+, ;A+; 10"A-9 92;6-9"

."89A<" $"P-2,6 9-:2" !"5A>2, ;A+; 11"2AF,? ;A+;"

/"P-2,6 96@ "2>8,-6 F-+,9 #"6 9,>9 ;A+;"

- 98-P968A,-: A-9 867P92269 76,69 &-++ @9-; ,5 89A< ? P>++?"89A< &-++ 96,A, A@ 76; ,5

P-2,6 96@ ,6 >P A@ @6& "&5-+ 76;-: @6&' P-2,6 868,@ ,6 P-2,6 96@ 2>8<2 ,5 A-9 ,596>:5

-+, ;A+;"A:A- @> ,6 89A< 96,A,-6 P-2,6 76;2 >P A@ 867P922 ,5 A-9",5 867P922@ A-9 76;2

,5 5A>2, ;A+; >P A@ 28AP2"P-2,6 9-:2 A9 P96;-@@ A96>@ P-2,6 -69@9 ,6 2A+ ,5

867P922@ A-9 A@ +>9-8A, ,5 8?+-@9"2>8,-6 F-+,9 -2 P96;-@@ - 69@9 ,6 A++6& 8+A A-9 ,6

8?+-@9"6 9,>9 ;A+; -2 P96;-@@ -69@9 ,6 P9;, ,5 9;92 F+6& 6F 867P922@ A-9" ,5

867P922@ A-9 &-++ :, F-++@ - ,5 A-9 929;6-9 >-,"A-9 929;-69 >-, -2 P96;-@@ - 69@9 ,6 2>PP+?

862,A, F+6& 6F A-9 ,6 ,5 +-" A 2AF,? ;A+; (P922>9 9+-F ;A+;) -2 P96;-@@ - ,5 929;6-9

F69 2AF,? P>9P62 "-F 867P92269 8@-: ,5 @2-9@ P922>9 9+-F ;A+; :, 6P@ >P A@

P922>9 &-++ :6 @6& .O3 =;<3C:ON =;<3C:ON COO# ;46 N == CO#34O3.O3 =3-4

CO#34O3 #43:4 =;< #;# == <4 #3OV646.



SCREWCOMPRESSOR



2crew compressor consists of two rotors' one male rotor and one female rotor" ,he male rotor has four

equally spaced helical lobes" ,he rotors used ha3e asymmetrical rotor profiles" ,his type of profile allows the

female rotor to be dri3en directly by the male rotor' a3oiding the need for synchroniBing gearwheels"

ecause the rotary screw compressor uses the positi3e displacement principle' the air deli3ery is directly

proportional to the rotation speed" ,he higher the speed' the larger the 3olume displaced by the compressor

element

1C ,he ends of the rotors unco3er the inlet and air enters the compression chamber"

.C ,he air is entrapped in the DcompartmentD formed by a male lobe and a female flute"

/C As the rotors turn' the compartment becomes progressi3ely smaller' thereby compressing the entrapped air"

%C 8ompressed air lea3es through the outlet port



Air flow E 1"Air inta*e filter C ."Air inta*e 3al3e C /"8ompression element C %"onCreturn 3al3e C $"6il separator element C

"7inimum pressure 3al3e C "After cooler C !"Air to air heat exchanger C #"&ater separator with drainC 10"Filter (optional)

6il flow E 11"6il reser3oir C 1."6il cooler C 1/",hermostatic bypass 3al3e C 1%"6il filter C 1$"6il stop 3al3e

9efrigeration flow E 1"9efrigerant compressor C 1"8ondenser C 1!"+iquid refrigerant dryer4filter C 1#"8apillary tube C

.0"3aporator C .1"5ot gas bypass 3al3e C .."Accumulator

Intake air. Air. Air/Oil mixture

Wet Air. Refrigerant. Oil



#34C;:ON N N6=N- :4 CO#34O3

• <4O34 O#4NN- N> #3: N64 :4 CO#34O3

;N=O6 == :4 #34;346 3 N6 4N;34 NO

#34;34 N64 CO#34O3.• N4V43 :O;C :4 =V4 34 N64 :4 CO#34O3.

• <4O34 O#4NN- :4 N64 #3: O CO#34O3

N4V43 O3-4: :O C=O4 :4 O;:=4: V=V4.

• :4#43:;34 O :4 CO#3446 O= O34.O

<4O34 CN-N- :4 O= ==O : :O COO=.

• N4V43 6A;: :4 4:> V=V4 4::N-.

• 6ONB: CN-4 :4 #34:43 4::N- ;N:=

O:434 : V43> ;C 44N:=.



N4V43 ==O 3 =4-4 N>434

A 27A++ 8A+8>+A,-6 6 A-9 +A<A:"

CON643 O;3 <- CO#34O3 'NO $* 3;NNN-.

C#C:> O CO#34O3 D 75 .

VO=;4 #3O6;C46 <> CO#34O3 D 500 C.

CON643 3 =4N- 3O EF<# ##4.

VO=;4 O 3 =4N- : G <3 #34;34 D 9H C.

O3 #3O6;CN- 500 C : N44646 75 .

:O #3O6;C4 9H C : 34I;34 3O;N6 $H.25 &3

O3 ON4 >43 > CO#34O3 =O646 O3 !000 3.

O : CON;4 $H.25 @ !000 H2J750 ;N: >43=>.

A9+? ."$ +A82 ,9A 862, -2 +62, F69 867PA?"

26 ;9 A++6& A-9 +A<A: - 867PA?"



PRESSURE REGULATOR FILTER – REGULATOR- LUBRICATOR

DIRECTION CONTROL VALVE AND SILENCER FLOW CONTROL VALVE



3=Bs

• F9+ stands for filter' regulator and lubricator • &hen an F9+ unit is referred to' it means a combination

of these three de3ices closely connected together

• ,hey form a unit that will prepare the condition of

compressed air Gust before deli3ering it to pneumaticequipment or machinery

• ,his ensures the air supply is clean and dry' the

pressure is at the correct le3el and fine particles of oil

are carried in the air to lubricate the wearing parts

within 3al3es' cylinders and tools• A con3enient method of combining these components

is to use a modular system



ilter 'general prin+iple*

2eparate and collectcontaminants

Angled lou3ers spin the

air as it enters the bowl

&ater droplets and large

solid particles spunoutwards against bowl

and run to the bottom

affle pre3ents turbulent

air splashing water on to

the filter element lement traps finer solid

particles

LOUVER

FILTER

WATER PARTICLES

DRAIN PLUG

SYMBOL



Compresse, air )uality

8lass

particlesiBe max

Hm

2olids

concentration

mg4m /

&ater

7ax Pressure@ew point 68

6il

concentrationmg4m /

1 0"1 0"1 1 0 0"01. 1 1 1 %0 0"1

/ $ $ 1 .0 1

% 1$ ! / $

$ %0 10 .$

C C 10 C

C C ot 2pecified C

maximum

Pressure dew point is the temperature to

which compressed air must be cooled before

water 3apour in the air starts to condense into

water particles

-26 !$/C1



#ressure regulator • :"is is a relie/ing regulator

to allo( pressure to bere,u+e, to a lo(er setting

• :urn anti+lo+K(ise to

re,u+e t"e spring for+e

• :"e "ig"er for+e un,er t"e,iap"ragm lifts it +lear of

t"e /al/e spin,le

• #2 +an no( ex"aust until

t"e ,iap"ragm seals

• :urn +lo+K(ise to a,Lust

up to t"e ne( pressure

P1 P.

.

%

!

10

%0!0

1.0

lbf4in.

bar



#ressure regulator • 9educes supply pressure

P1 to a suitable wor*ing

pressure P.• &hen there is no flow

demand the poppet 3al3e

closes to hold the

pressure at P.

• Flow demand will open thepoppet 3al3e wide enough

to satisfy the flow rate at

pressure P.

• P. can be set on a gauge

fitted to the regulator

.

%

!

10

%0!0

1.0

lbf4in.

bar

P1 P.



#ressure regulator • :o in+rease pressure #2J

pull t"e a,Lusting Knob upto ,isengage t"e lo+King

teet"

• :urn +lo+K(ise until ne(

#2 pressure rea+"e,

• :"e "ig"er spring for+e

pus"es t"e /al/e open

• :"e rising pressure #2

a+ts un,er t"e ,iap"ragm

to balan+e t"e spring an,allo( t"e /al/e to +lose

.

%

!

10

%0!0

1.0

lbf4in.

bar

P1 P.



ilter 3egulator

Filter and regulatordesigned as a single unit

Air is first filtered then

directed to the primary

side of the regulator

Pressure is then reducedto a wor*ing 3alue

6nly one unit to install

8ost sa3ing when

compared to two separate

units



=ubri+ation

• <een for effi+ient running of pneumati+ e)uipment an,

long life of seals an, (earing surfa+esJ +orre+t lubri+ationis essential

• or t"e best results lig"t lubri+ation is applie,+ontinuously from an air line lubri+ator. :"is is parti+ularlyrele/ant in a,/erse appli+ations ("ere t"ere may be "ig"spee, an, "ig" temperature running or ("ere t"e+on,ition of t"e +ompresse, air "as poor

• n a lubri+atorJ oil ,rips are atomise, an, t"e tiny oilparti+les form a /ery fine mist in t"e air supplying t"e

appli+ation



=ubri+ator ;nit

Oil is su+Ke, in yello( tube by

its pressure ,ifferen+e. ts

flo( (ill be +ontrolle, by

green Knob at top si,e.

Oil (ill ,rip as ,roplet an, it (ill

be+ome small ,roplet an,mixes at ,eli/ery air.

Normally re+ommen,e, oil is

V- !2.

P1

P.

P1

P.



Val/e :ypes• un+tion is t"e s(it+"ing

+omplexity of a /al/e

• "o(n by t(o figures 2&2J

!&2J H&2J 5&2J !&!J H&! ? 5&!

• irst figure is t"e number ofmain ports. nletsJ outletsJ an,

ex"austs ex+lu,ing signal

an, external pilot supplies

• e+on, figure is t"e number

of states• !&2 /al/e "as ! portsJ an, 2

statesJ normal an, operate,.



DIRECTION CONTROL VALVE



Val/e iMe• iMe refers to a /al/eBs port

t"rea,.

• or similarly ,esigne,

/al/es t"e amount of air

flo( t"roug" t"e /al/e

usually in+reases (it" t"eport siMe.

• #ort siMe alone "o(e/er

+annot be relie, upon to

gi/e a stan,ar, /alue of

flo( as t"is is ,epen,ent ont"e ,esign of t"e /al/e

internals.

• :"e port siMe

progression 5J3$&8 J

3$&HJ 3!&8 J 3$&2J 3!&HJ

3$.7$91 4!

91 4%

9/ 4!91 4.

9/

4%91



+tuator Control '!&2 /al/e*

• ! port /al/e pro/i,es t"e inletJ outlet an, ex"aust pat" an, is t"e normal

+"oi+e for +ontrol of a single a+ting +ylin,er

• n t"e normal position pro,u+e, by t"e springJ t"e /al/e is +lose,

• n t"e operate, position pro,u+e, by t"e pus" button t"e /al/e is open

• :"e pus" button must be "el, ,o(n for as long as t"e +ylin,er is outstroKe,

$2 $0

$

2

!$

2

!

$2 $0



+tuator Control '5&2 /al/e*

• fi/e port /al/e pro/i,es an inlet port $ t"at is s(it+"e, bet(een

t(o outlet ports 2 an, H ea+" (it" an ex"aust port ! ? 5• n t"e normal position pro,u+e, by t"e spring $ is +onne+te, to 2

(it" H to ex"aust 5

• n t"e operate, position pro,u+e, by pus"ing t"e button port $ is+onne+te, to H (it" 2 to ex"aust

$5 !

$2$H

H 2

$2$H

$5 !

H 2



5&! Val/e 'open ex"austs*• it" t"e spool in t"e mi, 'normal* position t"e supply port is seale,

an, outlet ports are to ex"aust

• pool rig"tJ port $ is Loine, to HJ port 2 is Loine, to !

• pool leftJ port $ is Loine, to 2J port H is Loine, to 5

$

2H

5 !

1% . /$

1% 1.



5&! Val/e 'open ex"austs*

• it" t"e spool in t"e mi, 'normal* position t"e supply port is seale,an, outlet ports are to ex"aust



$

2H

5 !

1% . /$

1% 1.



5&! Val/e 'open ex"austs*

• it" t"e spool in t"e mi, 'normal* position t"e supply port is seale,

an, outlet ports are to ex"aust



$

2H

5 !

1% . /$

1% 1.



• ,entifi+ation of t"e

+omponent parts of atypi+al 5&2 solenoi, /al/e

(it" spring return #

,ypical ;al3e

SOLENOID

PISTON

Spool with di! "#l V#l$" %od&

R"t'() p(i)*

Alt"()#ti$" po(t +,

P("'(" i)di!#to( M#)'#l o$"((id"El"!t(i! !o))"!to(



#ilot operate, 2&2 seat /al/e• prings pro/i,e ex+ellent

sealing in t"e normally +lose,

position

• ir pilot signal lifts t"e seat

against t"e spring

• n siMes -$&2 to -2 for "ig"

flo(

• uitable for /a+uum to up to

$G bar

• Can be +lose +onne+te, (it"a solenoi, pilot /al/e to

generate t"e pilot signal

8lic* the illustration to start and stop animation

AIR PILOT

INLET

SPOOL WILL LIFT W.EN AIR

ENTERD IN TO PILOT



lo( 3egulation• <y t"e use of flo(

regulators t"e outstroKespee, an, instroKe spee,

of a piston ro, +an be

in,epen,ently a,Luste,

• pee, is regulate, by

+ontrolling t"e flo( of air toex"aust

• :"e front port regulator

+ontrols t"e outstroKe

spee, an, t"e rear port

regulator +ontrols t"e

instroKe spee,

l l t



lo( regulator

• ;niD,ire+tionalJ line mounte, a,Lustable flo( regulator

1 ree flo( in one ,ire+tion

1 ,Lustable restri+te, flo( in t"e ot"er ,ire+tion



<anLo lo( 3egulator • 6esigne, to fit ,ire+tly in to

+ylin,er portsJ so pla+ing

a,Lustment at t"e appropriate

+ylin,er en,

• :(o types

1 One to gi/e +on/entional

flo( restri+tion out of t"e

+ylin,er an, free flo( in

'as illustrate,*

1:"e ot"er type to gi/erestri+te, flo( in to t"e

+ylin,er an, free flo( out

'not illustrate,*

-ui,e to Val/e iMe an, lo(



-ui,e to Val/e iMe an, lo(

• :"is grap" gi/es a gui,e to t"e to flo( range appropriate to ,ifferent /al/e

siMes• #ort siMe alone +an only be a roug" gui,eJ in,i/i,ual /al/e types (ill /ary

a++or,ing to ,esign

• :"e flo( /alues in,i+ate, by t"e /erti+al lines are

at #$ G barJ (it" $bar pressure ,rop

;al3e

siBe

91

9/ 4%

91 4.

9/ 4!

91 4%

91 4!

7$

10000000%.$0.$001.$0$0

.$0

Flow l4min



ntro,u+tion :o +tuators

• #neumati+ a+tuators in+lu,e linear +ylin,ers

an, rotary a+tuators.

• :"ey are ,e/i+es pro/i,ing po(er an, motion to

automate, systemsJ ma+"ines an, pro+esses.• pneumati+ +ylin,er is a simpleJ lo( +ostJ easy

to install ,e/i+e t"at is i,eal for pro,u+ing

po(erful linear mo/ement.

• pee, +an be a,Luste, o/er a (i,e range.

• +ylin,er +an be stalle, (it"out ,amage.



ntro,u+tion :o +tuators

• ,/erse +on,itions +an be easily tolerate, su+" as "ig"

"umi,ityJ ,ry an, ,usty en/ironments an, +leaning

,o(n (it" a "ose.

• :"e bore of a +ylin,er ,etermines t"e maximum for+e

t"at it +an exert.

• :"e stroKe of a +ylin,er ,etermines t"e maximum linear

mo/ement t"at it +an pro,u+e.

• :"e maximum (orKing pressure ,epen,s on t"e

+ylin,er ,esign. V6 +ylin,ers (orK up to $G bar.

• :"rust is +ontrollable t"roug" a pressure regulator.



<asi+ Constru+tion

1

.

/

%

$

!

#

10

11

1.

1/

1%

$ +us"ion seal

2 magnet

! +us"ion slee/e

H barrel

5 gui,e bus"

G ro, an, (iper seal 7 front en, +o/er

8 front port

9 ree, s(it+"

$0 piston ro,

$$ (ear ring

$2 piston seal$! rear en, +o/er

$H +us"ion s+re(

!'hio) "#l/#*)"t



ingle a+ting

• ingle a+ting +ylin,ers "a/ea po(er stroKe in one,ire+tion only

• Normally in• Normally out

8lic* the illustrations to start and stop animation



6ouble a+ting +ylin,er

• 6ouble +ting Cylin,er it"out Cus"ion

• 6ouble +ting Cylin,er it" ixe, Cusion.



6& a,Lustable +us"ions

• progressi/ely slo(s t"e piston ro, ,o(n o/er t"e last part of stroKe



ixe, +us"ion ,esign

• "o+K absorbent ,is+s set into t"e en, +o/ers+us"ion t"e impa+t of t"e piston



,Lustable +us"ion ,esign

• :"e piston is mo/ing to t"e left at spee,.

• ir is /enting t"roug" t"e +entre of t"e seal.



,Lustable +us"ion ,esign• :"e +us"ion seal is pus"e, to t"e left an, seals against itBs left "an, e,ge

an, insi,e ,iameter.• ir +an only es+ape past t"e +us"ion s+re(. :"e pressure buil,s up an,

+us"ions t"e piston.



,Lustable +us"ion ,esign• :"e s+re( is set to bring t"e pistonJ ro, an, loa, to a gentle "alt

against t"e en, +o/er.



,Lustable +us"ion ,esign• /al/e "as been operate, to po(er t"e piston out.

• :"e +us"ion seal is pus"e, to t"e rig"t. -roo/es in t"e rig"t "an,

e,ge an, outsi,e ,iameter bypass t"e s+re(.



,Lustable +us"ion ,esign

• :"e piston is starte, in t"e ot"er ,ire+tion unDrestri+te, by t"e

+us"ion s+re( setting.



3o,less +ylin,ers

• Contain t"e mo/ement pro,u+e, (it"in t"e same

o/erall lengt" taKen up by t"e +ylin,er bo,y.

• or exampleJ a+tion a+ross a +on/eyor beltJ or for

/erti+al lifting in spa+es (it" +onfine, "ea,room.

• o/ement is from a +arriage running on t"e si,e of t"e

+ylin,er barrel.

• slotJ t"e full lengt" of t"e barrel allo(s t"e +arriage to

be +onne+te, to t"e piston.

• =ong sealing strips on t"e insi,e an, outsi,e of t"e

+ylin,er tube pre/ent loss of air an, ingress of ,ust.




3o,less +ylin,er

• 6ouble a+ting (it" a,Lustable +us"ions




Operating prin+iple

• :"e sealing strips are parte, an, +lose, as t"e

piston mo/es t"roug" t"e stroKe

• ,Lustable +us"ions

• 6ual +onne+tion ports at t"e left "an, en,




=N:3 applie,

• or a+tion a+ross a

strip pro+ess

• No o/er"ang or

me+"anism re)uire,

+ompare, to a+on/entional piston

ro, +ylin,er

• :"e appli+ation s"o(s

a flying Knife typi+al ofuse in t"e paper

pro,u+tion in,ustry




aintenan+e of pneumati+ systems



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basic pneumatic training

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