Fluid Power

Systems
PNEUMATICS

UNIT 5

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SYLLABUS

Unit-5:

Directional Control Valves: Symbolic representation as per IS

1219 and IS 5599. Design and constructional aspects, poppet
valves, slide valves –spool valve.

Simple Pneumatic control: direct and indirect actuation of

pneumatic cylinder, Use of memory valve. Flow control valves and
Speed control of cylinders- supply air throttling and Exhaust air
throttling use of Quick exhaust valve.

Signal processing elements: Use of Logic gates – OR and AND

gates in pneumatic applications. Practical examples involving the
use of logic gates. Pressure dependent controls-types-
construction-practical applications. Time dependent controls-
principle, construction, practical applications. 10 Hrs
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Directional Control Valves

 Directional Control valves are mainly used to change the direction of

flow path of working medium or signal medium.

 Directional control valves are designated as per the following

functions:
Number of ports on the valves
Number of switching positions
Method of actuation
Method of reset
Design and constructional features

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Construction of 3/2 directional valve

Distributing
Outlet Spring
spool
port

Housing Exhaust Pressure inlet

port port

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Port Marking of Direction Control Valve

As per IS-1219 As per IS 5599

Supply Port P Supply Port 1

Exhaust Ports R & S Exhaust Port 3 & 5
Out put Ports A & B Out put Ports2 & 4
Pilot Port [Set ] Z Pilot Port [Set] 14
Pilot Port [Reset]Y Pilot Port [Reset]12

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Pneumatically operated directional Systems
control valve

The 5/2 directional control valves, operated by

pneumatic impulse is applied in various practical
solutions such as: pushing of loads; applying tools for
performing operations, opening/closing doors and
windows, stretch/bend of robot/manipulator arms.

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Pneumatically operated directional Systems
control valve

Control Valve Outlet

Control
input spool ports
input

Housing Exhaust
Exhaust Pressure
port
port inlet port

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Symbolic Representation

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Methods of Actuation

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Quick Exhaust Valve
 In many applications especially with single acting cylinders,
it is a common practice to increase the piston speed during
retraction of the cylinder to save the cycle time
 This is carried out by incorporating a Quick exhaust valve.
 The Quick exhaust valve has essentially three ports
 Supply port 1, is connected to the out put of the final control element
(Directional control valve). The Output port, 2 of this valve is directly
fitted on to the working port of cylinder. The exhaust port, 3 is left
open to the atmosphere

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Quick Exhaust Valve
Use of Quick Exhaust Valve

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Controlling of Pneumatic Cylinders

Pneumatic cylinders can be controlled by the following

methods:

1. Direct control of Single or Double acting cylinder

2. Indirect Control of Cylinder with Single Piloted Final Control

Valve

3. Indirect Control of Cylinder with Double Piloted Final

Control Valve

In the indirect control actuation, a pilot signal from a 3/2

N.C. valve is used to activate pilot ports of final control
valve.

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Direct Control of Single Acting Cylinder

Pneumatic cylinders can be directly actuated by actuation

of final control valve, manually or electrically

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Indirect Control of Single Acting Cylinder

Large cylinders as well as cylinders operating at high speed are

generally actuated indirectly as the final control valve is required
to handle large quantity of air.

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Use of Double Piloted Valve

Double piloted valve is also called as the Memory valve

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Use of Limit Switches

S1 S2

F=0

4 2
14 12

5 3
1
2 2
S1 S2

1 3 1 3

Use of Mechanically operated Roller lever Limit Switches

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Speed Control Of Cylinders

 It is always necessary to reduce the speed of cylinder from

maximum speed based on selected size of final control valve to
the nominal speed depending on the application

 Speed control of Pneumatic Cylinders can be conveniently

achieved by regulating the flow rate supply or exhaust air.

 The volume flow rate of air can be controlled by using flow

control valves which can be either Two way flow control valve or
One way flow control valve

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One-way flow control valve

 The pneumatic one-way flow control valve is also referred to as a

pneumatic throttle valve. Throttle valves are used in many
pneumatic systems to control air flow.

 There are two basic types of throttles - adjustable and non-

adjustable, the adjustable version is the most commonly used.
When using adjustable flow-control valves the user can adjust
the effective throttling area to best suit the air flow needs of the
individual application.

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Construction of flow control valve

Housing Regulating Spring

screw

Port 1 Check valve Port 2

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Speed Control of Cylinder
Parts List
Sl. No. Component Symbol Quantity
1 Double acting 1
cylinder

2 5/2 DCV – 1
Manually
operated, spring
return

3 Throttle check 2
valve

4 FRL Unit 1

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Speed Control of Cylinder

Supply air throttling / exhaust air throttling

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Supply air throttling / exhaust air throttling
Supply Air Throttling
• Supply air entering the cylinder through either of the working ports, undergoes throttling as the non
return valve is closed in the direction of flow.
• During exhaust , the compressed air leaving the cylinder is by passed through the non return valve
and escapes freely as it does not under go throttling
• Supply air throttling is used for single acting cylinder and small volume cylinder

Exhaust Air Throttling

• Supply air flows freely to the cylinder through the bypass passage of the non return valve. The
supply air does not under go any throttling
• Exhaust air leaving the cylinder has to under go throttling as the non return valve is closed in the
return direction
• The piston is loaded between two cushions of air
• Exhaust throttling should always be used for double acting cylinder
• Not suitable for small volume cylinders and cylinders with short strokes as effective pressure cannot
build up sufficiently.
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Signal processing elements

To meet the requirement of various conditions in pneumatic applications,

signal processing devices are often used. The following gates or valves are
used, depending on the required conditions.

• OR Gate – Shuttle Valve – Used to select one of the two input signals

• AND Gate- Two Pressure Valve- To combine two input signals i.e to
satisfy two conditions at the same time

• NOT Gate- 3/2 way, normally open, pilot operated Directional Control
Valve- used to negate the function

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Signal processing elements
Shuttle Valve as ‘OR’ gate

An Input Signal [1] can be applied on either side of the valve to

obtain an out put signal at port 2. A small aluminum or plastic
ball or spool is used as the shuttle which blocks the port
opposite to the input signal.

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Signal processing elements

Selection of Parts

Sl. No. Component Numbers

1 Double acting cylinder 1
2 5/2 Way Directional Control Valve 1
(Single Piloted)
3 3/2 way Push button valve (NC) 2
4 Shuttle valve 1
5 Air Service unit (Filter Regulator 1
assembly)

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Signal processing elements

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Signal processing elements
Twin Pressure Valve as ‘AND’ Gate

Input signal applied on any one side of the valve will block the signal
passage on the same side of the port.

If a second signal is applied on the opposite side at the same time,

it will be communicated to the out put port.

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Signal processing elements

Selection of Parts

Sl. No. Component Numbers

1 Double acting cylinder 1
2 5/2 Way Directional Control Valve 1
(Single Piloted)
3 3/2 way Push button valve (NC) 2
4 Twin pressure valve 1
5 Air Service unit (Filter Regulator 1
assembly)

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Signal processing elements

Circuit Diagram

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Signal processing elements

Not Gate

2
10

1 3

Not Gate is generally used to invert the signal status i. e to negate the
signal. For example a normally closed timer or counter can be converted to
normally open and vice versa

It is essentially a normally open 3/2 way, pilot operated directional control

valve. Input signal is applied at pilot port 10 and out put is taken from port 2.

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Logical Control With Shuttle Systems
And Twin-pressure Valves

Task:
The Piston of double acting cylinder of a supply station supplies work pieces under
the following logical conditions:

The start button (S0) or an auxiliary button (S1) is actuated and parts are available in
the work piece magazine (B2)

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Logical Control With Shuttle Systems
And Twin-pressure Valves

An optical display shows whether there are still enough

parts available in the magazine

The cylinder should only retract into its back end position
if it has actuation reached the front end position and an
acknowledgement button (S4) is actuated.

A 5/2 impulse valve is used as an actuator.

Additionally: for scanning work pieces in the magazine (B2) it is not possible lto use a
mechanically operated signaler.

The scanning should therefore occur in a non-contact manner through a reflex sensor.
The working speed of the cylinder should be infinitely adjustable in both directions

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Logical Control With Shuttle Systems
And Twin-pressure Valves

Pneumatic circuit

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Position Dependent Control

TASK:

• A Double acting cylinder is required to perform continuous

reciprocating motions on actuation of a detente manual push
button.

• The piston should extend and retract over the complete stroke
length as dictated by mechanical limit switches.

• The speed of travel of the piston should be adjustable both

during the forward and return motions.

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Position Dependent Control

Parts List

1 Double acting Cylinder 1

2 Double Piloted 5/2 way Valve 1

3 One way flow control valves 2

4 3/2 way Push button valve (NC) with 1

detent
5 3/2 way roller lever N.C. valve [Limit 2
switches]
6 Distributor manifold ( 6 fold) 1

7 Air Service unit (Filter Regulator 1

assembly)

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Position Dependent Control

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Pneumatic Timers

Figure : Pneumatic Timers- Normally closed and Normally Open

A Pneumatic Timer is a combination valve which consists of three parts

1. 3/2 way pilot operated directional control valve [NC or NO],
2. A one way flow control valve and
3. An accumulator

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Pneumatic Timers

e represents the signal status of input signal

a represents the signal status of output signal

Output signal appears after lapse of time t after input signal is Introduced in ON delay
timer while in OFF delay timer the out put signal disappears after a time lag after input
signal is introduced

0 state corresponds to no signal while 1 state corresponds to presence of signal

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Time Delay Valve [N.C]

Signal input is supplied at port 12 and delayed signal out put is taken at 2.
A signal source is connected at port 1

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Pneumatic Timers

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Circuit

 Manual remote start of a - +

double acting cylinder
a1

 Uses a low pressure A

operated valve connected

normally open
 When the back pressure in
4 2
the front of the cylinder 14 12
falls below 0.1 bar the
return signal is given 5 1 3
 Connection taken between
the cylinder and flow
regulator 12
2
10 10
2
12
 Useful for pressing work
pieces of variable size 3 1 1 3 0.1bar

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Electrical Relays

The term Relay generally refers to a device that provides an electrical

connection between two or more points in response to the application of a
control signal. The most common and widely used type of relay is the
Electromechanical Relay or EMR.

As their name implies, Electromechanical Relays are Electro-Magnetic

devices that convert a magnetic flux generated by the application of an
electrical control signal either AC or DC current, into a pulling mechanical
force which operates the electrical contacts within the relay.

The most common form of electromechanical relay consist of an energizing

coil called the "Primary Circuit" wound around a permeable iron core. It has
both a fixed portion called the Yoke, and a moveable spring loaded part
called the Armature, that completes the magnetic field circuit by closing the
air gap between the fixed electrical coil and the moveable armature.

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Electrical Relays

This armature is hinged or pivoted and is free to move within the

generated magnetic field closing the electrical contacts that are
attached to it. Connected between the yoke and armature is normally
a spring (or springs) for the return stroke to "Reset" the contacts back
to their initial rest position when the relay coil is in the "de-energized"
condition, ie. turned "OFF".

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Relay Contacts
The relays contacts are electrically conductive
pieces of metal which touch together complete a
circuit and allows the circuit current to flow, just
like a switch.

When the contacts are open the resistance

between the contacts is very high in the Mega-
Ohms, producing an open circuit and no circuit
current flows.

When the contacts are closed the contact

resistance should be zero a short circuit, but this is
not the case. All relay contacts have a certain
amount of "contact resistance" when they are
closed and this is called the "On-Resistance". With
a new relay and contacts this on-resistance will be
very small, generally less than 0.2Ω's because the
tips are new and clean.

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Electro-pneumatic Logic

AND Logic

The relay circuit controlling the valve provides an AND logic function.

To operate the solenoid Y, and extend the cylinder, it is necessary to push

buttons S1 AND S2 simultaneously

If any of these two buttons is released, the cylinder will retract

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Electro-pneumatic Logic

OR Logic

The relay circuit controlling the valve provides an OR logic function.

To operate solenoid Y and extend the cylinder, it is necessary to push

button S1 OR S2 or both

However, both must be released for the cylinder to retract

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Electro-pneumatic Logic

MEMORY Logic

The push button A+ is operated to turn on the relay RR1, which closes both
contacts R1 and R2.

The push button A+ can be released as the first contact (R1) is providing
continuity to hold the relay on.

At the same time, the second contact (R2) operates the solenoid Y to extend
the cylinder.
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Electro-pneumatic Logic

MEMORY Logic

This state will continue until the normally closed push button contact A− is
opened, whereupon the relay will de-energize and both contacts R1 and
R2 will open.

The push button A− can now be released and the relay remains off. At the
same time, the solenoid is de-energized, causing the cylinder to retract

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Electrical Control for Double Systems
Solenoid Valve

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