PNEUMATIC & HYDRAULIC

SYSTEMS

CHAPTER SIX

PNEUMATIC SYSTEM DESIGN

AND DEVELOPMENT

Dr. Ibrahim Naimi

Symbols And Standards In

Pneumatics
The development of pneumatic systems is assisted
by a uniform approach to the representation of
the
h elements
l andd the
h circuits.
i i The h symbols
b l usedd
for the individual elements must display the
following characteristics:
• Actuation and return actuation methods.
• Number of connections.
• Number of switching positions.
• General operating principle.
• Simplified representation of the flow path.

1
 Symbols And Standards In
Pneumatics
The technical construction of the
component is not taken into account in
the abstract symbol form. The symbols
used in pneumatics are detailed in the
standard DIN ISO 1219, "Circuit
Circuit
symbols for fluidic equipment and
systems".

2
3
4
5
6
7
8
9
 Control Valves

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
 Development of pneumatic systems
The solution to a control problem is worked out according
to a system with documentation playing an important
role in communicating the final result. The circuit
diagram should be drawn using standard symbols and
l b li Comprehensive
labeling. C h i documentation
d t ti is
i required
i d
including most of the following:
• Function diagram
• Circuit diagram
• Description of the operation of the system
• Technical
T h i l data
d t on the
th components t
Supplementary documentation comprising:
• Parts list of all components in the system
• Maintenance and fault-finding information
• Spare parts list

Design of the circuit diagram

Control Chain
(Control System Representation)

28
 Design of the circuit diagram
The circuit diagram shows signal flow and the
relationship between components and the air
connections. The structure of the circuit diagram
should correspond to the control chain, whereby
the signal flow is represented from the bottom to
the top. Simplified or detailed symbols may be
used for the representation of the circuit diagram.
In the case of larger circuit diagrams, the power
supply
l parts (service
( i unit,i shut-off
h ff valve,
l various
i
distributor connections) are shown on a separate
page of the drawing for the purpose of
simplification

29
 Circuit Diagram

30
 Designation of individual elements
Signal elements should be represented
in the normal position in the circuit
diagram. If valves are actuated in the
initial position as a start precondition,
this must be indicated by the
representation of a trip cam.
cam In this
case, the actuated switching position
must be connected.

Designation by numbers
With this type of designation, elements are divided
into ggroups.
p Groupp 0 contains the elements for the
power supply, groups 1,2,... designate the
individual control chains. One group number is
generally allocated for each cylinder.

31
 Designation by Letters
This type of designation is used primarily for a
systematic
y development
p of circuit diagrams.
g Here,,
limit switches are allocated to the cylinder,
which acknowledges them.

Example:
Typical problem:
The piston rod of a double-acting
pneumatic cylinder advances if either a
manual push button or a foot pedal is
operated. The cylinder returns to its starting
position slowed down after fully extending.
Th piston
The i rodd will
ill return provided
id d the
h
manual actuators have been released.

32
 Example:
Solution:
The roller lever valve 1S3 is positioned as a limit
switch in the forward end pposition of the cylinder.
y The
circuit diagram shows this element situated at the signal
input level and does not directly reflect the orientation of
the valve. The mark on the circuit at the extended
cylinder position indicates the physical position of the
limit switch 1S3 for circuit operation. If the control is
complex
p and contains several workingg elements,, the
control should be broken down into separate control
chains, whereby a chain is formed for each cylinder.
Wherever possible, these chains should be drawn next to
each other in the same order as the operating sequence.

33
 Summery
• Physical arrangement of the elements is ignored.
• Draw the cylinders and directional control valves
horizontally wherever possible.
• The energy flow within the circuit moves from the
bottom to the top.
• Energy source can be shown in simplified form.
• Show
Sh elements
l in
i the
h initial
i i i l position
i i off the
h control.
l
Identify actuated elements by a cam.
• Draw pipelines straight without cross-over
wherever possible.

34
 Control System Development
The development of the control system solution requires
that the problem is defined clearly. There are many ways
of representing the problem in a descriptive or graphical
form. The methods of representing the control problem
include:
• Positional sketch
• Motion diagram:
- Displacement-Step Diagram.
- Displacement
Displacement-Time
Time Diagram.
• Control chart
• Function diagram
• Function chart
• Circuit diagram

Positional sketch
The positional sketch shows the
relationship between the actuators and the
machine fixture. The actuators are shown
in the correct orientation. The positional
sketch is not normally to scale and should
not be too detailed. The diagram will be
used in conjunction with the description
of the machine operation and the motion
diagrams.

35
 Positional Sketch

Motion diagram
The displacement-step diagram and the
displacement-time diagram are used for motion
sequences. Theh di
displacement-step
l di
diagram
represents the operating sequence of the actuators;
the displacement is recorded in relation to the
sequence step. If a control system incorporates a
number of actuators,, theyy are shown in the same
way and are drawn one below the other. Their
interrelation can be seen by comparing the steps.

36
 Displacement-step diagram

Displacement-step diagram
In this case there are two cylinders 1A
and 2A. In step 1 cylinder 1A extends
and then cylinder 2A extends in step 2.
In step 3 cylinder 1A retracts and in
step 4 cylinder 2A retracts. Step number
5 is equivalent to step 1.
1

37
 Displacement-time diagram
In the case of a displacement-time diagram, the
displacement is plotted in relation to the time.

Control chart
In the control chart, the switching status of the
control element is represented in relation to the
steps or the
h time.
i The
h switching
i hi time
i is i not taken
k
into account. The control diagram in the following
figure shows the statuses of the control
components (1V for cylinder 1A and 2V for
cy1inder
y 2A)) and the status of the limit switch 1S1
fitted at the front end position of the cylinder 1A.

38
 Control chart

Function diagram

The function diagram is a combination

of the motion diagram and the
control chart.
chart The lines representing
the individual states are referred to as
function lines.
lines

39
 Function diagram

Function diagram
Apart from the function lines, signal lines can also be
entered in the function diagram. The signal line output is
at the signal element and the end at the point, where a
change
g in status occurs,, dependent
p on this signal.
g Arrows
on the signal lines indicate the direction of signal flow.
Signal branching are denoted by a dot at the point of
branching. Several changes in status of components are
introduced by a signal output. In the case of the OR
condition, a dot is placed at the point of conjunction of the
signal
g lines. Several signal
g outputsp effect the same change g
in status irrespective of one another. The AND condition
is designated by means of an oblique stroke at the point of
conjunction of the signal lines. A change in status only
occurs, if all signal outputs are present.

40
 Representation of signal lines

Representation of input elements

41
 Example:

The diagram illustrates the following sequence:

• If the limit switch 2S1 is actuated and the push button
1S1 is pressed by the operator, the piston rod of cylinder
1A extends.
• When the cylinder 1A reaches its forward end position,
the limit switch 1S3 is actuated and the piston rod of
cylinder 2A advances.
• When the cylinder 2A reaches its forward end position,
the limit switch 2S2 is actuated and the piston rod of
cylinder 1A retracts.
• When the cylinder 1A reaches its retracted end position,
position
the limit switch 1S2 is actuated and the piston rod of
cylinder 2A retracts.
• When cylinder 2A reaches its retracted end position, the
limit switch 2S1 is actuated and the initial position is
reached again.

42
 Abbreviated notation
Abbreviated notation is another possibility of representing motion
sequences. In this case, the cylinder designations 1A, 2A, etc. are
used in the sequence. The signal for advancing is designated using
a ‘+’
+ and the signal for retracting using a ‘-‘
-.
• The sequence 1A+ 2A+ 2A- 1A- is to be read as follows:
Cylinder 1A advances, cylinder 2A advances, cylinder 2A retracts,
cylinder 1A retracts. Sequential movements are written consecutively.
• The sequence 1A+ 2A+ 2A-
1A- is to be read as:
C li d 1A advances,
Cylinder d cylinder
li d 2A advances
d andd cylinder
li d 1A retracts,
cylinder 2A retracts. Simultaneous movements are written vertically

Function chart
The function chart gives a clear picture of action, and
reactions in sequences. The diagram describes the
following sequence:
• The clamp cylinder 1A is extended (1A+) and the limit
valve
l then
h operatedd is i 1S2.
1S2
• This limit 1S2 initiates the extension of cylinder 2A
(2A+) which is the riveting process.
• The riveting cylinder fully extends and operates the
limit 2S2. The limit 2S2 initiates the retraction of the
riveting cylinder (2A-).
• The limit 2S1 is then operated which initiates the
movement of cylinder 1A unclamping and retracting
(1A-).
• The full retraction of cylinder 1A is indicated by the
limit 1S1 and this is the initial condition required for a
new cycle to commence.

43
 Function chart

Circuit diagram
The circuit diagram shows signal flow and the relationship
between components and the air connections. There is no
mechanical layout
y representation
p with the circuit diagram.
g
The circuit is drawn with the energy flow from the bottom
to the top. The various levels of a circuit include the energy
source, signal inputs, signal processing, control elements
and the actuators. The position of the limit valves are
marked at the actuator. Components and lines are identified
b the
by h component numbering
b i system andd the h port (way)
( )
connection numbers. These allow cross reference to the
components on the actual machine and make the circuit
readable.

44
 Circuit diagram

The life cycle of a pneumatic

system
The development of solutions for
pneumatic control systems is
dependent upon methodical planning.
The various phases involved in the life
cycle of such systems from the initial
problem to upgrading the system are
shown here.

45
 Development of Pneumatic circuits
- Development of single actuator circuits:
• Direct control of a pneumatic cylinders.
• Indirect control of a pneumatic cylinders
cylinders.
• Logic functions: AND, OR, …
• Memory circuit and speed control of a cylinder.
• The quick exhaust valve.
• Pressure dependent control.
• The time delay valve.

- Development of multiple actuator circuits

46
 Development of single actuator circuits
Direct control of a pneumatic cylinders
The simplest level of control for the single or double-
acting cylinder involves direct control signals. With this,
the
h cylinder
li d isi actuatedd directly
di l via i a manually
ll or
mechanically actuated valve, without any intermediate
switching of additional directional control valves. If the
port sizes and the flow values of the valve are too large,
the operating forces required may be too great for
di t manuall operation.
direct ti Reference values
al es for limits of
direct cylinder control:
• Cylinder with piston diameter smaller than 40 mm
• Valves with connection sizes smaller than 1/4"

47
 Example 1:
A single-acting cylinder of 25 mm
diameter is to clamp a component when a
pushh button
b iis pressed.
d As
A long
l as the
h pushh
button is activated, the cylinder is to remain
in the clamped position. If the push button
is released, the clamp is to retract.

48
 Positional sketch

Solution:
The control valve used for the single-acting cylinder is
the 3/2-way valve. In this case, since the cylinder is of
small capacity, the operation can be directly controlled
by a push button 3/2-way directional control valve with
spring return
return. On operating the push button the air passes
through the valve from port 1 to 2 via the valve 1S into
the piston chamber of the cylinder 1A. The pressure
builds up and advances the piston rod against the force
of the cylinder return spring. On release of the button,
the valve spring returns the 3/2-way valve to its initial
position and the cylinder retracts. The air returns from
the cylinder via the exhaust port 3. Components which
are the only one of their type are designated without 2
supplementary number Since the cylinder is the only
working element in the circuit, it is designated 1A. In
this and the following circuit diagrams, the service unit
(0Z) and the start-up valve (0S) have also been drawn in.

49
 Circuit Diagram

Circuit Diagram

50
 Try to draw the following:
• Motion diagram:
- Displacement-Step Diagram.
- Displacement-Time Diagram.
• Control chart.
• Function diagram.
• Function chart.

Example 2:
A double-acting cylinder is to extend when
a push button is operated. Upon release of
the
h pushh button
b the
h cylinder
li d isi to retract.
The cylinder is of small bore (25 mm
diameter) requiring a small flow rate to
operate at the correct speed.

51
 Positional sketch

Try to draw the following:

• Motion diagram:
- Displacement-Step Diagram.
- Displacement-Time Diagram.
• Control chart
• Function diagram
• Function chart
• Circuit diagram

52
 Circuit Diagram

Circuit Diagram

53
 Circuit Diagram

Solution:
The following manually operated directional control valves can be
used as control elements:
• 5/2-way valve.
• 4/2-way valve
In the initial position, the valve is unactuated, pressure is applied at
the piston rod side and the piston rod of the cylinder is retracted.
On operating the push button, the air passes through the valve
from 1 to the 4 port and advances the piston rod. The displaced air
flows to atmosphere via the ports 2 and 3. On release of the push
button, the valve spring returns the control valve to its initial
position and the cylinder retracts. Air returns from the cylinder via
the exhaust port 5. The push button is released, the direction of
movement is immediately reversed and the piston rod retracts. It is
therefore possible to change the direction of movement without
the piston rod reaching its initial or end position.

54
 Indirect control of a pneumatic cylinder
Cylinders with a large piston diameter have a
high air requirement. A control element with high
nominal flow rate must be used to actuate these.
these
If the force should prove too high for a manual
actuation of the valve, then an indirect actuation
should be constructed, whereby a signal is
generated via a second smaller valve, which will
provide
id the
h force
f necessary to switch
i h the
h controll
element.

Example 3:
A single-acting cylinder with a
large
g ppiston diameter is to clampp a
workpiece following actuation of a
push button. The cylinder is to
retract once the push button is
released.
l d

55
 Positional sketch

Solution:
In the initial position, the single-acting cylinder 1A is retracted. A
springreturn 3/2-way pneumatic valve is used to actuate the cylinder.
Connection 1 of the valve 1V is closed, connection 2 is exhausted to
atmosphere via connection 3. The valve 1S is actuated when the push
button is activated and ppressure is applied
pp to the control port
p 12 of the
control valve 1V. The control valve 1V is actuated against spring
force and is thus switched to flow. The pressure building up at the
cylinder piston causes the cylinder piston rod of the single-acting
cylinder to extend. The signal at the control port 12 remains as long
as the push button is operated. Once the piston rod has reached end
position, it returns only after the push button has been released. When
the ppush button is released,, the valve 1S returns to its initial pposition.
Control port 12 of the control valve 1V exhausts to atmosphere and
the signal is reset. The control valve also returns to initial position.
The return spring causes the cylinder to retract. The air from the
cylinder chamber is exhausted to atmosphere via the control valve.

56
 Circuit Diagram

Try to draw the following:

• Motion diagram:
- Displacement-Step Diagram.
- Displacement-Time Diagram.
• Control chart.
• Function diagram.
• Function chart.

57
 Example 4:
A double-acting cylinder is to
advance when a ppush button is
operated. Upon release of the push
button the cylinder is to retract. The
cylinder is 250 mm diameter and
consumes a large
l volume
l off air.
i

Positional sketch

58
 Solution:
For controlling cylinders at high speed or of large
diameter, the air flow required determines that a large size
control valve should be used. The operating force to actuate
the valve may be relatively large and in this case indirect
control is preferable. The valve 1S when operated by a push
button supplies a pilot signal to the 14 port of the control
valve 1V. The valve 1V reverses, the piston rod of the
cylinder is pressurised and the piston rod of cylinder 1A
advances. If the push button is released, the control port of
valve 1V exhausts to atmosphere. The valve 1V then reverses
and the cylinder retracts. If the push button is released, the
direction of movement is immediately reversed and the
piston rod retracts. A change in the direction of movement is
therefore possible without the piston rod reaching its initial
or end position. Since the valve 1V is without memory
function, it changes its switching position immediately after
the push button of valve 1S has been pressed.

Try to draw the following:

• Motion diagram:
- Displacement-Step Diagram.
- Displacement-Time Diagram.
• Control chart
• Function diagram
• Function chart
• Circuit diagram

59
 Circuit Diagram

Circuit Diagram

60
 Logic Functions
The pneumatic shuttle valve and the dual pressure
valve have logic functions. Both have two inputs
and one output each
each. The shuttle valve has the
characteristic of an OR function, whereby at least
either of two inputs 1 or 1(3) are required to
generate an output at port 2 of the valve. In the
case of the dual pressure valve, the characteristic is
that
h off the
h A AND ffunction,
i whereby
h b bboth h iinputs 1
and 1(3) are required to initiate an output 2.

Example 5:
The piston rod of a double-acting
cylinder
y is to advance when the 3/2-
way roller lever valve 1S2 is actuated
and the push button of the 3/2-way
valve 1S1 is actuated. If either of these
are released,
l d then
h the h cylinder
li d is
i to
return to the initial position.

61
 Solution:
The inputs 1 and 1(3) of the dual-pressure valve 1V1 are connected to
the working ports 2 of the valves 1S1 and 1S2. The 3/2-way roller lever
valve 1S2 is actuated by the insertion of a workpiece and then creates a
signal at one input of the dual-pressure valve. Since only one input is
actuated, the AND condition has not been fulfilled and the output of the
dual-pressure valve remains closed. If the push button of the 3/2-way
valve 1S1 is now also actuated, a signal will also be applied at the
second input. The AND condition is now fulfilled and a signal is
generated at the output 2 of the dual-pressure valve. The 5/2-way
pneumatic valve 1V2 switches, the piston side of the cylinder is
pressurised and the piston rod advances. If one of the two valves 1S1 or
1S2 is no longer actuated
actuated, then the AND condition will no longer be
fulfilled and the signal at the output of the dual pressure valve will be
reset. The signal pressure at the control port 14 of the control element
1V2 is exhausted to atmosphere via the reset valve 1S1 or 1S2. The
control element 1V2 switches back. The pressure building up on the
piston rod side ensures the retraction of the piston rod.

Circuit Diagram

62
 Alternative solution
An alternative solution to using the dual
pressure valve is to use two 3/2- way valves in
series.
i Here
H th the signal
i l isi passedd from
f push-h
button valve 1S1 to the roller lever valve 1S2
and then on to the control element 1V2 but
only if both valves 1S1 and 1S2 are operated,
i e when the AND condition is met
i.e. met. When a
valve is released, the signal at the control
element is reset and the piston rod retracts.

Circuit Diagram

63
 Try to draw the following:
• Motion diagram:
- Displacement-Step Diagram.
- Displacement-Time Diagram.
• Control chart.
• Function diagram.
• Function chart.

Example 6:
The piston rod of the cylinder 1A is to
advance only y if a workpiece
p is inserted in
the workpiece retainer, a guard has been
lowered and the operator presses the push
button valve. Upon the release of the push
button or if the guard is no longer in its
lower position, the cylinder 1A is to retract
to the initial position.

64
 Positional sketch

Solution:
The logic AND operation of the output signals of valves 1S1,
1S2 and 1S3 is checked by the dual-pressure valves 1V1 and
1V2. If the valves are actuated, i.e. 1S2 (via the workpiece),
1S3 (via the guard) and 1S1 (via the operator)
operator), a signal is
applied at output A of the dual-pressure valve 1V2. This
signal is passed on to the control port 14 of the control
element 1V3. The valve 1V3 reverses, pressure is applied at
the piston side of the cylinder 1A and the piston rod
advances. If the push button is released or the guard opened,
this means that the AND conditions are no longer met. The
control port 14 of the valve 1V3 is unpressurised. The valve
1V3 switches and the piston rod retracts.

65
 Try to draw the following:
• Motion diagram:
- Displacement-Step Diagram.
- Displacement-Time Diagram.
• Control chart
• Function diagram
• Function chart
• Circuit diagram

Circuit Diagram

66
 Circuit Diagram

Circuit Diagram

67
 Example 7:

A double-actingg cylinder
y is to
advance if one of two push buttons is
operated. If the push button is then
released, the cylinder is to retract.

Solution:
The inputs 1 and 1(3) of the shuttle valve 1V1 are connected
to the working connections of the valves 1S1 and 1S2. Upon
operation of one of the push buttons, the corresponding valve
1S1 or 1S2 is actuated and a signal is generated at the 1 or
1(3) side of the shuttle valve. The OR condition is fulfilled
and the signal passes through the shuttle valve and is emitted
at port 2. The signal pressure is prevented from escaping via
the exhaust of the unactuated valve by closing the line in the
shuttle valve. The signal effects the switching of the control
element 1V2. The piston side of the cylinder is pressurised
and the piston rod advances. When the actuated push button
is released, the signal pressure is relieved via the valves 1S1
and 1S2 and the control element is switched back to its initial
position. The pressure now building up on the piston rod side
ensures the retraction of the piston rod.

68
 Circuit Diagram

Try to draw the following:

• Motion diagram:
- Displacement-Step Diagram.
- Displacement-Time Diagram.
• Control chart.
• Function diagram.
• Function chart.

69
 Example 8:

A double-acting cylinder is to
advance
d if one off two
t pushh buttons
b tt is
i
operated. When reaching its fully
extended position, the cylinder is to
retract.

Solution:
A double pilot valve should be fitted for the control of the
cylinder. If the cylinder is to retract on reaching its fully
extended position, roller lever valves should be used as limit
valves to confirm that this position has been reached
reached. One of
the push buttons need only be operated for a short duration
and the cylinder will fully extend, since the effect of the
signal at input 14 of the 5/2-way double pilot valve 1V2 is
maintained until a signal is applied at input 12. As soon as
the piston rod has reached the forward end position, the limit
switch 1S3 generates a signal at input 12, and the valve 1V2
is reversed. The retracted end position of the piston rod can
also be sensed. This requires an additional limit switch.

70
 Circuit Diagram

Alternative Solution:
The addition of the dual pressure valve 1V2 and the
roller limit switch 1S4 ensures that the cylinder is
fully retracted before the cylinder can be extended
again. The condition for a renewed advancing of the
piston rod is the actuation of one of the valves 1S1 or
1S2 and the limit switch 1S4. When the cylinder is
advanced at position 1S3, the cylinder retracts even if
the
h valves
l 1S1 andd 1S2 are still
ill operatedd since
i the
h
limit switch 1S4 is inactive.

71
 Circuit Diagram

Circuit Diagram

72
 Circuit Diagram

Try to draw the following:

• Motion diagram:
- Displacement-Step Diagram.
- Displacement-Time Diagram.
• Control chart.
• Function diagram.
• Function chart.

73
 Example 9:
A double-acting cylinder is used to
transfer parts from a magazine. If either a
push button or a foot pedal is operated,
the cylinder is to advance. Once the
cylinder is fully advanced, it is to retract
to the initial p
position. A 3/2-wayy roller
lever valve is to be used to detect the full
extension of the cylinder.

Positional sketch

74
 Solution:
The logic OR operation of the output signals of valves 1S1
and 1S2 is checked by the shuttle valve 1V1. Upon operation
of either the push button of valve 1S1 or the pedal of valve
1S2, a signal is generated at the 1 or 1(3) side of the shuttle
valve. The OR condition is met and the signal is passed to the
control port 14 of the valve 1V2. The valve 1V2 switches,
pressure is applied to the piston side of the cylinder 1A, and
the cylinder advances. If the actuation (push button or pedal)
of the valve is released, the signal at the control port of valve
1V2 is reset. Since valve 1V2 is a double pilot valve (with
memory function), its switching position does not change.
The limit switch 1S3 is actuated, when the piston rod reaches
its end position. A signal is then applied at the control port 12
of the valve 1V2. The valve 1V2 reverses and the piston rod
retracts. If the limit switch 1S3 is released during retracting,
the direction of movement can be changed by actuating the
push button or the pedal, even if the piston rod has not yet
reached its initial position.

Try to draw the following:

• Motion diagram:
- Displacement-Step Diagram.
- Displacement-Time Diagram.
• Control chart
• Function diagram
• Function chart
• Circuit diagram

75
 Circuit Diagram

Circuit Diagram

76
 Circuit Diagram

Self-holding Circuit (Dominant OFF)

77
 Self-holding Circuit (Dominant ON)

78
79
80
81
 Speed Control
Fundamentally, there are three types of
throttling circuits for double-acting cylinders:
• Supply air throttling:
(Meter-in Speed control)
• Exhaust air throttling:
(Meter-out Speed control)
• Bleed-off Speed Control.
(Bypass Speed control)

82
 Meter-in Speed Control
(Supply air throttling)
For supply air throttling, one-way flow control
valves are installed so that the air entering the
cylinder
li d isi throttled.
h l d The h exhaust
h air
i can escape
freely through the check valve of the throttle
valve on the outlet side of the cylinder. The
slightest fluctuations in the load on the piston rod,
such as occur for example when passing a limit
s itch lead to very
switch, er large irregularities
irreg larities in the feed
speed. A load in the direction of movement of the
cylinder accelerates the cylinder beyond the set
value. Therefore supply air throttling can be used
for single-acting and small volume cylinders.

Meter-in Speed Control

(Supply air throttling)

83
 Meter-in Speed Control
(Supply air throttling)
In some applications, the flow control valve is
placed upstream from the actuator. This
application
li i is i called
ll d a meter-in
i circuit
i i because
b it
i
controls, or meters, the rate of flow going into the
actuator. The meter-in circuit is used to control
actuator speed where the actuator constantly
works against a load. This means that there is
al a s resistance to flow
always flo downstream
do nstream from the
valve. For example, a cylinder used to push a
load might be controlled with the meter-in circuit
shown in the following figure. A check valve is
often included to allow a rapid return stroke.

Meter-in Speed Control

(Supply air throttling)

84
 Meter-out Speed Control
(Exhaust air throttling)
With exhaust air throttling, the supply air flows freely
to the cylinder and the exhaust air is throttled. In this
case, the piston is loaded between two cushions of air.
The first cushion effect is the supply pressure to the
cylinder and the second cushion is the exhausting air
being restricted at the one-way flow control valve
orifice. Arranging throttle relief valves in this way
contributes substantially to the improvement of feed
behaviour. Exhaust air throttling should be used for
double-acting cylinders. In the case of miniature
cylinders, supply and exhaust air flow control is to be
selected because of the reduced air quantity.

Meter-out Speed Control

(Exhaust air throttling)

85
 Meter-out Speed Control
(Exhaust air throttling)
When the actuator does not constantly work
against a load, such as in a drilling operation
where
h the h ddrill
ill breaks
b k through
h h the
h stock,
k a meter-
out circuit may be used. A meter-out circuit
controls the flow rate leaving the actuator. A
meter-out circuit that controls the extension speed
of a cylinder is shown in the following figure. In
this circuit,
circ it gravity
gra it applies a constant force that
attempts to extend the cylinder. If the meter-out
needle flow control valve was not included, the
cylinder might extend too quickly, creating a
runaway condition.

Meter-out Speed Control

(Exhaust air throttling)

86
 Bleed-Off Speed Control
(Bypass)
Speed control is also achieved using the bypass
configuration.
g In this configuration,
g , a needle
valve is connected between the air supply and the
cap end of the cylinder as shown in the following
figure. The opening of the needle valve controls
the flow of compressed air that is exhausted to
atmosphere This configuration is less power
atmosphere.
efficient but only one needle valve is required
to control the speed in both directions.

Bleed-Off Speed Control

(Bypass)

87
88
 Piston speed
The piston speed of pneumatic cylinders is
dependent on the:
• Load.
• Air pressure.
p essu e.
• Piston size.
• Length of pipe.
• Cross-sectional area of the line between the
control element and the working element.
• Flow rate through the control element.
Acceleration of pneumatic cylinders to
maximum stroking speed takes place very quickly
within a few millimeters of starting the stroke.

89
 Circuits for Cylinder Speed Regulation

• Reducing the speed: this is achieved by using:

- Throttle
Th ttl valves.
l
- Hydraulic Check unit.
- Cushioning.
- Hydraulic
y Damper
p ((Dashpot).
p )

• Increasing the speed: this is achieved by

using quick exhaust valve.

Speed Reduction Using Throttles

Depending on the type of equipment, there are

three possibilities which can be considered:
1- Constant, non-adjustable restriction.
(The speed is constant during the stroke)

90
 Speed Reduction Using Throttles

2- Throttle constant over the stroke, but

manually adjustable.
adjustable
(The speed is constant during the stroke,
but manually adjustable)

Speed Reduction Using Throttles

3- Throttle continuously adjustable over the
stroke by using mechanically adjustable flow
control valve
valve.
(The speed is variable during the stroke)

A control cam coupled to the piston rod varies

the restrictor during the stroke.

91
 Speed Reduction Using Hydraulic
check units
If the speed is to be slowed down further, hydraulic
braking may be considered. This entails coupling the air
cylinder to a hydraulic check unit.
unit The separate piston
rods of pneumatic cylinder and hydraulic check unit
cylinder are jointed by a Yoke. Speed of motion is then no
longer controlled by the air power but through the flow
control valve installed in the hydraulic circuit. The oil flow
lends itself to better and preciser control than compressed
air Design considerations limit use of hydraulic check
air.
units to strokes no more than about 650 mm. Using a
hydraulic check unit, speed of pneumatic linear actuator
can be controlled down to about 30 mm/min.

92
 Speed Reduction Using cushioning and hydraulic dashpot

93
 Increase Speed Using Quick exhaust valve

Quick-exhaust valves are used to increase the

piston speed of cylinders
cylinders. This enables lengthy
return times to be avoided, particularly with single
acting cylinders. It is advantageous to mount the
quick-exhaust valve directly on the cylinder or as
near to it as possible.

94
95
96
 Example 10: Memory circuit and speed control
of a cylinder
The piston rod of a double-acting cylinder is to
advance when a 3/2-way push button valve is
actuated manually. The cylinder is to remain
advanced until a second valve is actuated. The
signal of the second valve can only take effect
after the first valve has been released. The
cylinder
li d isi to
t then
th return
t to
t the
th initial
i iti l position.
iti
The cylinder is to remain in the initial position
until a new start signal is given. The speed of the
cylinder is to be adjustable in both directions.

97
 Solution:
4/2-way or 5/2-way double pilot valves possess the
required memory function. The valve retains its last
switched
it h d position
iti untiltil an opposing
i signal
i l is
i
received. This characteristic is independent of the
time period, for which the signal is applied to the
switching valve. The one way flow control valves
control the cylinder speed in both directions and are
independently adjustable. Since the displaced air
flow is restricted in each case, this is an exhaust air
flow control.

Circuit Diagram

98
 Circuit Diagram

Example 11:
A double-acting cylinder is to be used to transfer parts from a
magazine. The cylinder is to advance fully when a push button is
operated and then retract automatically. Full extension is confirmed
by a roller lever valve. The cylinder is to continue forward even if
th pushh button
the b tt isi released
l d before
b f full
f ll extension
t i is i reached.
h d The
Th
speed of the cylinder is to be adjustable in both directions of motion.
1. What is the effect on the piston rod movement, if the push button
remains actuated once the piston rod has reached the end position?
2. What is the effect on the advance stroke, if the roller lever valve is
fitted at the stroke mid position of the piston rod?
3. Describe the initial status of the system.
4. Describe the operation of the circuit.

99
 Positional sketch

Solution:
4/2-way or 5/2-way double pilot valves possess the
required memory function. The valve retains its last
switched
it h d position
iti untiltil an opposing
i signal
i l is
i
received. This characteristic is independent of the
time period, for which the signal is applied to the
switching valve. The one way flow control valves
control the cylinder speed in both directions and are
independently adjustable. Since the displaced air
flow is restricted in each case, this is an exhaust air
flow control.

100
 Circuit Diagram

Answer to question 1
The limit switch 1S2 is actuated, when the piston
rod reaches its end position. If the push button 1S1
remains
i pressedd in
i this
thi status,
t t a reversall off the
th
valve 1V1 is not possible, since a signal is applied
at both control ports 12 and 14. The first signal
applied 14 is dominant. The signal at control port
12 is ineffective. The piston rod remains in the
extended status. The piston rod cannot be retracted
until the push button 1S1 has been released and
the control port 14 becomes unpressurised.

101
 Answer to question 2
If the roller lever valve 1S2 is fitted at the stroke
mid-position, then the piston rod retracts again
upon reaching this position
position. However,
However this is not
possible unless the push button 1S1 has already
been released again. If the push button 1S1 has not
yet been released at this point, the piston rod
overtravels the limit switch 1S2 and travels up to
y
the cylinder stop.
p A return stroke is not ppossible
unless the roller lever valve has been manually
actuated or with the help of the manual override of
the control element 1V1.

Answer to question 3
Both valves 1S1 and 1S2 are unactuated in the
initial position. The switching position of the valve
1V1 isi suchh that
th t connections
ti 1 andd 2 andd
connection 4 and 5 are each interconnected. With
this, pressure is applied at the piston rod side of
the cylinder 1A and the piston rod remains in the
retracted status.

102
 Answer to question 4
If push button 1S1 is actuated, a signal is applied at the
input 14 of the valve 1V1. The valve 1V1 switches,
pressure is applied at the piston side of the cylinder 1A
and the piston rod advances. Upon reaching the end
position, the piston rod actuates the limit switch 1S2, and
a signal is applied at the control port 12 of the valve 1V1.
This reverses and the piston rod retracts. The speed of the
piston rod is set via the adjusting screw on the flow
control valves 1V2 and 1V3 (exhaust air flow control).
After each of the valves 1S1 and 1S2 has been released,
the control ports become pressureless. The use of a double
pilot valve (valve 1V1 has a memory function) ensures
that the switching position does not change.

Example 12: The quick exhaust valve

The combined actuation of a manually actuated

valve and a roller lever valve advances a forming
tool on an edge-folding device. The forming
tool is driven by a double-acting cylinder. For
rapid forward travel, the circuit utilises a quick
exhaust valve. The retracting speed is to be
adjustable. If either of the two valves are released,
the tool returns to its initial position.

103
 Positional sketch

Solution:
In the initial position, the inserted workpiece actuates the roller lever
valve 1S2. The quick exhaust valve 1V4 is closed to atmosphere,
pressure is applied at the piston rod side of the cylinder 1A, and the
piston rod remains in the retracted status. If the start button 1S1 is
actuated, a signal is applied at both inputs 1 and 1(3) of the dual-
pressure valve
l 1V1.
1 1 The h AND
A condition
di i isi met andd the
h signal
i l isi passedd
to the control port 14 of the control element 1V2. The valve 1V2
switches, pressure is applied to the piston side of the cylinder 1A, and
the piston rod advances. As a result of the valve 1V2 reversing, input 1
of the quick exhaust valve 1V4 becomes pressureless. The air displaced
on the piston rod side of the cylinder during advancing opens the quick
exhaust valve and flows directly to atmosphere via the output 3. The
flow resistance,, created byy the valve 1V2 and the lines against
g the
displaced air, no longer applies. The piston rod is able to advance more
rapidly. If one of the two valves 1S1 or 1S2 is released, the AND
condition at the dual-pressure valve 1V1 is no longer met. The final
control element 1V2 switches, the quick exhaust valve 1V4 closes and
the piston rod retracts. The retracting speed is set at the restrictor of the
one-way flow control valve 1V3.

104
 Circuit Diagram

Example 13: Pressure dependent control

A plastic component is embossed using a die

di
driven by
b a double-acting
d bl ti cylinder.
li d TheTh die
di is
i to
t
advance and emboss the plastic when a push
button is operated. The return of the die is to be
effected when a preset pressure is reached. The
embossing pressure is to be adjustable.

105
 Positional sketch

Solution:
If the piston rod is not in its initial position, the circuit must be reset by operating the
manual override on the 5/2-way double pilot valve. All valves are unactuated in the
initial position, pressure is applied at the piston rod side of the cylinder and the piston
rod remains in the retracted state. Actuation of the push button switches the valve 1S
to flow and a signal is applied at the control port 14 of the double pilot valve 1V2.
The valve 1V2 switches, pressure is applied at the piston side of the cylinder and the
piston
i rodd advances.
d The
h switching
i hi status off the h double
d bl pilot
il valvel 1V2
1 2 remains
i intact
i
if the push button 1S is released. When the piston rod reaches the workpiece, travel is
stopped and pressure starts to build up on the piston side. The increasing pressure
causes the force of the die to increase. The control port 12 of the pressure sequence
valve 1V1 is connected to the pressure line on the piston side of the cylinder 1A.
When the pressure in the cylinder reaches the value set on the pressure sequence
valve, the 3/2-way valve switches. A signal is now applied at the control port 12 of
the valve 1V2. The valve 1V2 switches, pressure is applied at the piston rod side of
the cylinder and the piston rod retracts. During retraction, the response pressure set on
the pressure sequence valve is not met and the pressure sequence valve returns to its
initial position. The response pressure set on the pressure sequence valve must be
lower than the system pressure in order to ensure reliable switching. Should the
advancing piston rod meet an obstacle, then it will retract again before reaching the
embossing position.

106
 Circuit Diagram

Example 14: Pressure dependent control;

embossing of plastic components

A plastic component is embossed using a die

poweredd by
b a ddouble
bl acting
ti cylinder.
li d The
Th return
t off
the die is to be effected when the cylinder rod has
fully extended to the embossing position and the
preset pressure is reached. A roller lever valve is to
be used to confirm full extension. The signal for
retracting must only be generated when the piston
rod has reached the embossing position. The
pressure in the piston chamber is indicated by a
pressure gauge.

107
 Positional sketch

Solution:
In the initial position, valves 1S1 and 1S2 are unactuated, pressure is
applied at the piston rod side of the cylinder 1A and the piston rod
remains in the retracted state. If necessary, the circuit needs to be put
into its initial position with the help of the manual override on the
control element 1V2. A signal is applied at the control port 14 of the
control element 1V2, if the push button 1S1 is actuated. The valve 1V2
switches, pressure is applied at the piston side of the cylinder 1A, and
the piston rod advances. If the push button 1S1 is released, the
switching position of the double pilot valve 1V2 does not change due to
its memory function. Just before reaching the forward end position
(embossing position), the limit switch 1S2 is actuated. The actuated
roller lever valve 1S2 releases the pressure line 1 to the pressure
sequence valve 1V1.1V1 During the embossing process,
process the pressure on the
piston side starts to increase. The indicator of the pressure gauge turns
to the right. When this pressure reaches the value set at the control port
12 of the pressure sequence valve, the 3/2-way valve of the pressure
sequence valve switches. The control element 1V2 reverses and the
piston rod retracts. During the retracting movement, the limit switch
1S2 is released and the signal at the control port 12 of the valve 1V2 is
reset and the pressure sequence valve is also reset.

108
 Circuit Diagram

Example 15: The time delay valve

A double-acting cylinder is used to press

t th glued
together l d components. t Upon
U operation
ti off a
push button, the clamping cylinder extends. Once
the fully advanced position is reached, the cylinder
is to remain for a time of T= 6 seconds and then
immediately retract to the initial position. The
cylinder retraction is to be adjustable. A new start
cycle is only possible after the cylinder has fully
retracted.

109
 Positional sketch

Solution:
If the piston rod is not in its initial position, the circuit must be reset by
operating the manual override on the 5/2-way double pilot valve. In the
initial position, all valves with the exception of the roller lever valve 1S2
(limit switch) are unactuated. Pressure is applied at the piston rod side of
y
the cylinder and the piston
p rod remains in the retracted state. Valve 1S1
and the limit switch 1S2 must be actuated as a start condition. The limit
switch 1S2 is not actuated unless the piston rod is in its initial position. If
the start condition is fulfilled, the dual-pressure valve 1V1 is switched to
flow and a signal is applied at the control port 14 of the double pilot
valve 1V3. The valve 1V3 reverses, pressure is applied at the piston side
of the cylinder and the piston rod advances. The advancing speed is
dependent on the setting of the one-way flow control valve 1V5 (exhaust
air control)
control). After a short advancing travel,
travel the piston rod releases the
limit switch 1S2. Following this, the AND condition at the dual-pressure
valve 1V1 is no longer met and the signal at the control port 14 of the
double pilot valve 1V3 is reset, whilst its switching position (stored)
does not change.

110
 Solution:
A renewed actuation of the valve 1S1 is now ineffective until the
system has reached its initial status again. When the embossing position
is reached, the limit switch 1S3 is actuated. The air reservoir in the time
delay valve 1V2 starts filling up via the integrated one-way flow control
valve. The rate of pressure increase is dependent on the setting of the
i
integrated
d restrictor.
i When
h the h pressure isi sufficiently
ffi i l high,
hi h the
h 3/2-way
3/2
valve switches and a signal is applied at the control port 12 of the double
pilot valve 1V3. The valve 1V3 reverses, pressure is applied at the piston
rod side of the cylinder and the piston rod retracts. The retracting speed
is dependent on the setting of the one-way flow control valve 1V4.
When retracting, the limit switch 1S3 reverses and the air reservoir of
the time delay valve 1V2 is exhausted to atmosphere via the non-return
valve and the limit switch 1S3. As result of this,, the 3/2-wayy valve of the
time delay valve switches into its initial position. The signal at the
control port 12 of the double pilot valve 1V3 is then reset. When the
piston rod reaches its initial position, the limit switch 1S2 is actuated and
a new cycle can be started.

Circuit Diagram

111
 Example 16: The time delay valve

A double-acting cylinder is used to press

together glued components. Upon operation of a
push button
button, the clamping cylinder slowly
advances. Once the fully extended position is
reached, the cylinder is to remain for a time of
T = 6 seconds and then immediately retract to the
initial position. A new start cycle is only possible
after the cylinder has fully retracted and after a
delay of 5 seconds. During this delay the finished
part is manually removed and replaced with new
parts for gluing. The retracting speed should be
fast, but adjustable.

Positional sketch

112
 Solution:
In the initial position, the roller lever valve 1S2 is actuated by the piston rod and
the time delay valve 1V1 is switched through, i.e. the working port 2 supplies a
signal. The piston rod side of the cylinder 1A is pressurised and the piston rod
remains in the retracted state. The following start condition must apply:
• Roller lever valve 1S2 is actuated.
• Time delay valve 1V1 is switched through.
• Start button is actuated.
If the roller lever valve 1S2 is actuated for a sufficiently long time period (t1 = 5
seconds), then the air reservoir of the time delay valve 1V1 is filled and the
corresponding 3/2-way valve is switched, following which a signal is applied at
input 1(3) of the dual-pressure valve 1V2. If the push button 1S1 is actuated, the
AND condition at the dualpressure valve is met. A signal is applied at the control
port 14 of the control element 1V4. The valve 1V4 switches, pressure is applied to
the piston side of the cylinder 1A and the piston rod advances. After a short
advancing distance, the limit switch 1S2 is released, pressure is reduced in the air
reservoiri off the
h time
i delay
d l valvel 1V1
1 1 viai the
h roller
ll lever
l valve
l 1S2,
1S2 andd the
h
integrated 3/2-way valve switches back to its initial position. The AND condition at
the dual-pressure valve is now no longer met. Actuation of the push button 1S1
becomes ineffective.

Solution:
Upon reaching the advancing position, the piston rod actuates the
roller lever valve 1S3. The pressure line to the time delay valve 1V3 is
now released and pressure in the air reservoir is increased. The rate of
pressure increase is adjustable via the integrated flow control valve.
When the switching pressure has been reached,
reached the integrated 3/2-way
3/2 way
valve switches and a signal is applied at the control port 12 of the final
control element 1V4. The valve 1V4 reverses and the piston rod
retracts. Upon release of the limit switch 1S3, the time delay valve
1V3 switches to its initial position again. The limit switch 1S2 is
actuated, when the piston rod reaches its initial position. The pressure
in the air reservoir of the time delay valve 1V1 starts to increase until
the switching pressure has been reached after t2 = 5 seconds.
seconds The
integrated 3/2-way valve switches. The initial status of the system is
now reached again and a new cycle can be started. The piston rod
speed is set at the restrictors of the one-way flow control valves 1V5
and 1V6 (exhaust air flow control).

113
 Circuit Diagram

Circuit Diagram

114
 Development of Multiple actuators circuits
Control of multiple actuators
In the case of multiple cylinder circuits, a clear definition of the
problem is important. The representation of the desired motion of
all actuators is described using the displacement-step diagram. The
special
i l conditions
diti for
f the
th start
t t off the
th sequence mustt alsol be
b
defined. If the motion diagram and auxiliary conditions have been
clearly defined, drawing of the circuit diagram can commence. In
order for a circuit to operate, it is essential to avoid overlapping
signals. By an overlapping signal, we understand signals applied
simultaneously at the two control ports of a double pilot valve.
The following valves can be used to eliminate signal overlap:
roller
ll llever valves
l with
i h idle
idl return or toggle
l lever
l valves,
l time
i
delay valves, reversing valves or sequencers. To provide a better
understanding of the methods, some examples are given for the
use of roller lever valves with idle return and reversing valves.

Example 17: Coordinated motion

Two cylinders are used to transfer parts from a

magazine onto a chute. When a push button is
pressed,
d the
th first
fi t cylinder
li d extends,
t d pushinghi the
th partt
from the magazine and positions it in preparation
for transfer by the second cylinder onto the out
feed chute. Once the part is transferred, the first
cylinder retracts, followed by the second.
Confirmation of all extended and retracted
positions are required.

115
 Positional sketch

Displacement-step diagram

116
 Circuit Diagram

Circuit Diagram

117
 Solution:
Roller lever valves with idle return are to be used as limit
switches to detect the return and advance positions of the
piston rod. The manual signal input is effected via a 3/2-
way y valve. In the initial pposition,, both cylinders
y are in the
retracted state, the limit switches 2S1 and 1S2 are actuated.
The start condition for a cycle is that the limit switch 2S1
and push button 1S1 must be actuated. The motion cycle
can be determined from the displacement-step diagram and
is subdivided into the following steps:

Solution:
1. If push button 1S1 is actuated, the 5/2-way double pilot valve 1V2
switches, and the piston rod of the cylinder 1A advances. The part is
ejected from the magazine.
2. When cylinder 1A reaches the forward end position, the limit switch
1S3 is
i actuated.
t t d The
Th 5/2-way
5/2 d bl il t valve
double-pilot l 2V ththen switches
it h andd
the piston rod of the cylinder 2A advances. The part is moved onto a
chute.
3. When cylinder 2A reaches its forward end position, the limit switch
2S2 switches. This causes the control element 1V2 to switch and the
piston rod of the cylinder 1A retracts.
4. When the retracted end position of the cylinder 1A has been reached,
the limit switch 1S2 switches and the control element 2V switches.
The piston rod of the cylinder 2A retracts and actuates the limit switch
2S1 upon reaching its retracted end position.
5. The initial position of the system has now been reached again. A
new cycle can be started by actuating the push button 1S1.

118
 Differentt P
Diff Pneumatic
ti
Circuits

119
120
121
122
123
 Electropneumatic System

124
 Example 18: Sorting Device

Positional sketch

125
 Pneumatic Circuit Diagram

Electrical Circuit Diagram

126
 Example 19: Assembly Station

In an assembly station components are to be

put together.
together By pressing two pushbutton
switches the device is advanced and the
components are assembled. After releasing
one or the two pushbutton switches, the
device is returned to its start position.

Positional sketch

127
 Solution:
By pressing the pushbutton switches S1 and S2, the
electric circuit for the solenoid coil 1Y is closed and
the 3/2-
3/2 (5/2-)
( /2 ) way solenoid valve is reversed. The
piston rod of the single-acting (double-acting) cylinder
advances to the forward end position. After releasing
the pushbutton switches S1 and S2 the electric circuit
for the solenoid coil 1Y is opened and the 3/2- (5/2-)
way solenoid valve is switched back to its initial
position by a reset spring. The piston rod of the
single-acting (double-acting) cylinder returns to the
retracted end position.

Pneumatic Circuit Diagram

128
 Electrical Circuit Diagram

129