Pneumatics Problems

Experiment No: 1 (a)

Aim: Operation of a single acting cylinder.

Problem description: The allocating device supplies aluminium valve blanks to a machining
station. By operating a push button, the piston rod of the single acting cylinder is made to
advance. After releasing the actuating button, the piston rod returns.

Apparatus: Single acting cylinder, 3/2 way valve with push button normally closed.

Working of the circuit:

Step 1-2
Through operating the 3/2 way valve via the push button, air is applied to the chamber on the
piston rod side of cylinder. The piston rod of the cylinder advances, and pushes a valve blank out
of the magazine. If valve continues to be operated, the piston rod remains in the forward end
position.

Step 2-3
After releasing the valve actuating button, the air in the cylinder is exhausted via the 3/2 way
valve. The force of the return spring pushes the piston back to its initial position. The valve
blanks are supplied from the magazine by gravity.
Experiment No: 1 (b):
Aim: Use of 3/2 way valve with push button normally open type.

Apparatus: Single acting cylinder, One way flow control valve, Quick exhaust valve, 3/2 way
valve with push button normally open type

Problem description: The parcel separating device feeds parcel post from a sloping conveyor
slide to an X-ray appliance.

Operating a push button causes very rapid retraction of the single acting cylinder with the
attached parcel tray. After releasing the valve actuator, the piston rod advances. Forward motion
time of the cylinder is to be variable.

Working of the circuit:

In the initial position, the single acting cylinder is advanced. The piston chamber is pressurized
via the 3/2 way normally open push button valve.

Step 1-2
By actuating the 3/2 way push button valve, the volume of air in cylinder is exhausted via the
quick exhaust valve. The cylinder returns rapidly. If the push button continues to be actuated, the
piston rod remains in the retracted end position. The next parcel slides into the parcel tray.

Step 2-3
If the valve actuator is then released, the piston rod advances and lifts the parcel. The desired
time of advance is set by means of the one way flow control valve.
Experiment No: 1 (c)
Aim: Operation of a double acting cylinder, Quick exhaust valve, Dual pressure valve.

Problem description: Operation of two identical valves by push button causes the forming tool
of an edge folding device to thrust downwards and fold over the edge of a flat sheet. If both or
even just one push button is released, double acting cylinder slowly returns to the initial position.

Apparatus: Double acting cylinder, One way flow control valve, Quick exhaust valve, Single
pilot 5/2 valve, Dual pressure valve, 3/2-way valve with push button normally closed – 2 Nos.

Working of the circuit: In the initial position, the piston rod of cylinder assumes the retracted
end position. The power valve is in the left hand switching position.
Step 1-2
If both the 3/2-way valves are actuated, pressure is applied at the output of the dual pressure
valve. The 5/2 way valve reverses. The piston chamber of cylinder is supplied with unrestricted
compressed air via the one way flow control valve. The cylinder travels to its forward end
position. As the chamber on the piston rod side is rapidly exhausted through the quick exhaust
valve, the cylinder motion is very fast. If both 3/2 way valves remain actuated, the cylinder
remains in the forward end position.
Step 2-3
If at least one of the push buttons is released, power valve is no longer pressurized. The valve
reverses through the spring. The actuator travels to its initial position under conditions of flow
restriction
Experiment No: 1 (d)
Aim: Use of dual pressure valve, Shuttle valve, Double pilot 5/2 way valve

Problem description: Surveyor’s measuring rods in 3 or 5 m length are marked in red with 200
mm graduations. There is a choice of two push buttons to start the forward movement of
measuring rods via cylinder, which has the exhaust air throttled. The idle stroke, also started by a
push button, can only take place when the double acting cylinder has reached its forward end
position.

Apparatus: Double acting cylinder, One way flow control valve, Double pilot 5/2 valve, Dual
pressure valve, Shuttle valve, 3/2-way valve with push button normally closed – 3 Nos., 3/2-way
roller lever valve normally closed.

Working of the circuit: In the initial position, the piston rod of cylinder assumes the retracted
end position. The pilot operated 5/2 way bi-stable valve with memory supplies air to the piston
rod chamber and exhausts the chamber on the inlet side of the piston.

Step 1-2
If at least one of the 3/2 way push button valves is actuated, memory valve reverses and the
piston rod advances slowly with throttled exhaust air - with this the surveyor’s measuring rod is
pushed forward. In the forward end position, the piston rod actuates the roller lever valve by
means of the trip cam. If no push button has been actuated, the cylinder remains in the forward
end position.

Step 2-3
After pressing the push button of the directly actuated 3/2 way valve for the return stroke,
memory valve reverses – the piston rod is rapidly retracted.

The commencement of the return stroke through the push button can be initiated only when the
forward end position has been reached and roller lever valve thus actuated. If a counter signal is
present at 5/2-way valve, the return stroke cannot be initiated.
Experiment No: 2 (a)
Aim: Use of time delay valve normally closed.

Problem description: A double acting cylinder guides cylinder pins towards a measuring
device. The pins are separated by means of a continuous to and fro movement. The oscillating
motion can be started by means of a valve with selector switch.

The duration of forward stroke and return stroke of the cylinder is to be adjustable. The cylinder
is to remain in the forward end position for t = 5 seconds.

Apparatus: Double acting cylinder, One way flow control valve-2 Nos, Double pilot 5/2 valve,
5/2 way valve with selector switch, Dual pressure valve, 3/2-way roller lever valve normally
closed – 2 Nos, Time delay valve normally closed.

Working of the circuit: In the initial position the piston rod of the cylinder assumes the
retracted position. The trip cam actuates the roller lever valve. One of the two start conditions is
fulfilled.

Step 1-2
If the detente valve is actuated, the second condition of the dual-pressure valve is fulfilled, and
the final control element is switched through. The piston rod extends with exhaust air throttled.
The duration of the advance stroke is adjusted with one way flow control valve. In the forward
end position, the trip cam actuates the roller lever valve. The time delay valve is pressurized. The
reservoir is filled via the restrictor. After the set time of t = 5.0 seconds, the 3/2 way valve of the
time delay valve is switched. A one signal is present at the output port. The final control element
returns to its initial position.

Step 2-3
Reversing the memory valve causes the piston rod to retract with exhaust air throttled. The
duration of return stroke is set by means of the one way flow control valve. When the roller lever
valve is re actuated, the return stroke is carried out.
Continuous cycle
If the start valve is de pressed and remains in the actuated position, the piston rod carries out a
continuous to and fro movement. Only when the detent is returned to its initial position, is the
motion sequence concluded at the end of the cycle.
Experiment No: 2 (b)
Aim: Use of pressure sequence valve normally closed.

Problem description: Badges are to be produced from a very thin metal sheet.

A press with a stamping die is available for this purpose. The double acting cylinder should
extend when both the push buttons S1 and S2 are pressed simultaneously. The return stroke is to
occur automatically only after the forward end position and preset pressure have been reached to
get the consistent quality.

The cylinder should immediately retract if emergency push button E is pressed.

Apparatus: Double acting cylinder, Pressure gauge, One way flow control valve, Dual pressure
valve, Shuttle valve, Double pilot 5/2 way valve, 3/2 way valve with push button normally
closed – 2 Nos. , 3/2-way roller lever valve normally closed, Pressure sequence valve.
Working of the circuit: In the initial position, the cylinder assumes the retracted end position.
The final control valve supplies pressure to the chamber on the piston rod side of the cylinder.
Step 1-2
If both the push buttons are actuated, the dual pressure valve passes on a signal to the 5/2 way
valve on its left side. This causes the reversal of the final control element. The cylinder extends
slowly with supply air throttled. The pressure regulator limits the pressure to a maximum of p =
4 bar. In the forward end position, the trip cam of the cylinder actuates the roller lever valve S1.
This causes pressure to be applied to the pressure sequence valve. The pressure sequence valve is
actuated when a pressure of p = 3 bar has been reached in the piston chamber. Adjust the flow
control so that the slow increase in pressure causes the cylinder to pause in the forward end
position.
Step 2-3
Once the pressure sequence valve has been switched, the final control element is reversed
through the shuttle valve. The cylinder travels to its initial start position. In the case of
emergency, the push button valve E is actuated during the forward stroke. It will reverse final
control element immediately and the cylinder will retract.
Experiment No: 2 (c)
Aim: Use of pressure sequence valve normally closed and time delay valve.

Problem description: An electrically heated welding rail is pressed onto a rotatable cold drum
by a double acting cylinder and welds a continuous plastic sheet into pieces of tubing. The
forward stroke is triggered by means of a push button. The maximum cylinder force is set at 4
bar via a pressure regulator with pressure gauge (This prevents the welding rail damaging the
metal drum). The return stroke is not initiated until the forward end position has been
acknowledged and the pressure in the piston area has reached 3 bar.
The supply air is restricted for the movement of the cylinder. Restarting is only possible when
the retracted end position has been reached and a time of t = 2 seconds has elapsed. Reversing a
5/2 way valve with selector switch causes the control to be switched to continuous cycle.

Apparatus: Double acting cylinder, One way flow control valve, Pressure gauge, Dual pressure
valve, Shuttle valve, Double pilot 5/2 valve, 5/2 way valve with selector switch, 3/2-way valve
with push button normally closed, 3/2-way roller lever valve normally closed – 2 Nos, Time
delay valve normally closed, Pressure sequence valve.

Working of the circuit: In the initial position, the cylinder assumes the retracted end position.
The final control valve supplies pressure to the chamber on the piston rod side of the cylinder.
The roller lever valve is depressed and the time delay valve is actuated. A one signal is present at
the right hand input of the dual pressure valve.

Step 1-2

If the push button is actuated, the shuttle valve passes on a signal to the dual pressure valve. This
causes the reversal of the final control element. The cylinder extends slowly with supply air
throttled. The pressure regulator limits the pressure to a maximum of p = 4 bar. In the forward
end position, the trip cam of the cylinder actuates the roller lever valve. This causes pressure to
be applied to the pressure sequence valve. The pressure sequence valve is actuated when a
pressure of p = 3 bar has been reached in the piston chamber. Adjust the flow control so that the
slow increase in pressure causes the cylinder to pause in the forward end position.
Step 2-3
Once the pressure sequence valve has been switched, the final control element is reversed. The
cylinder travels to its initial start position. Re actuation of the roller lever valve causes power to
be supplied to the pilot port of the time delay valve. Once the specified time of t= 2 seconds has
elapsed, the dual pressure valve is supplied with air to the right of the time delay valve so that a
renewed start is possible.

Continuous cycle

If the selector switch of the valve is reversed, the control is switched to continuous cycle.
Returning the detent to its initial position causes the control to stop at the end of the cycle.
Experiment No: 3 (a)
Aim: Controlling the stroke length of a double acting cylinder using roller lever valve.

Problem description: After the liquid paint colors have been poured together into a bucket, they
are mixed in by the vibrating machine.

When a push button has been pressed, the extended cylinder retracts completely and executes a
to and fro movement in the rear stroke range. The oscillating is limited to the retracted end
position by a roller lever valve as well as a second roller lever valve in the central position. The
frequency of oscillating is adjustable within its limits by setting a pressure regulator controlling
the amount of air supply. Set an operating pressure of p = 4 bar.

After a specified interval, the oscillator is switched off. The double acting cylinder extends
completely and actuates the third roller lever valve. Set a vibration time of t = 5 seconds.

Apparatus: Double acting cylinder, Double pilot 5/2 way valve – 2 Nos., Shuttle valve, 3/2-
way valve with push button normally closed, 3/2-way roller lever valve normally closed – 3 Nos,
Time delay valve normally closed.

Working of the circuit: In the initial position, the cylinder assumes the forward end position and
actuates the roller lever valve. The final control element assumes the right hand switching status.
The memory valve is also in the right hand switching position.
Step 1-2
Actuating the push button valve reverses the memory valve. Air is present at the pilot port of the
time delay valve. The final control element is reversed via the actuated roller lever valve and the
shuttle valve; the cylinder retracts. Traveling over the roller lever valve does not yet have any
effect. The trip cam actuates the roller lever valve in the retracted end position.
Step 2-3
With the roller lever valve actuated, the final control element reverses. The cylinder partially
extends and actuates the central roller lever valve.
Step 3-4
The cylinder is reversed again by actuation of the central roller lever valve. The reversing
procedure for the valves, and lasts only a few milliseconds so that the trip cam does not travel
over the roller lever valve.
Step 4-5
See step 2-3
Oscillating movement
The cylinder oscillates backwards and forwards between the roller lever valves until the
specified time of t = 5 seconds has expired.
Steps n-2 to n
After the time delay valve has been switched, the memory valve is reversed. Roller lever valves
are no longer supplied with compressed air. The cylinder travels to the initial position (forward
end position).
Experiment No: 3 (b)
Aim: Use of pneumatic counter

Problem description: Washers for injection pumps are to be cleaned in a cleaning bath. A
double acting cylinder is used to dip a container with washers in and out of the cleaning bath. A
push button is used to start the cleaning cycle. After reaching the forward end position, cylinder
should oscillate between roller lever valves S2 and S3 for 10 times and on completion should
stop in retracted position, S1. Next cycle should be possible only after 20 seconds.

Apparatus: Double acting cylinder, Double pilot 5/2 way valve – 2 Nos., Shuttle valve, 3/2-
way valve with push button normally closed, 3/2-way roller lever valve normally closed – 3
Nos., Time delay valve normally closed, pneumatic counter.

Working of the circuit: In the initial position, the cylinder assumes the retracted position
position and actuates the roller lever valve S1. The final control element assumes the left hand
switching status.

Step 1-2
Compressed air will be available in the inlet side of the push button valve after a delay time set
in the time delay valve. Actuating the push button valve reverses the memory valve and the
cylinder will extend. Traveling over the roller lever valve S2 will give signal to the counter to
decrement. At the end of the stroke roller lever valve S3 gets pressed.
Step 2-3
With the roller lever valve S3 actuated, the final control element reverses. The cylinder retracts
and actuates the central roller lever valve S2.
Step 3-4
The cylinder is reversed again by actuation of the central roller lever valve. The reversing
procedure for the valves, and lasts only a few milliseconds so that the trip cam does not travel
over the roller lever valve.
Step 4-5
See step 2-3
Oscillating movement
The cylinder oscillates forwards and backwards between the roller lever valves until the counter
gets decremented to zero.
Steps n-2 to n
When the counter gets decremented to zero due to the actuation of S2, the counter will release an
output signal and reverse position of the memory valve(with port no. 4 blocked). Roller lever
valve S2 is no longer supplied with compressed air. After actuation of S3, the cylinder will
retract and pressing of S2 will not have any effect. The air supply from the output of time delay
valve will reset the counter and counter output again gets blocked. The cylinder will retract to the
initial position and press S1 and will be ready for the next cycle after the time delay.
Experiment No: 3 (c)
Aim: Simultaneous actuation of multiple cylinders.

Problem description: Quarry stones are fed from a crushing roller to two vibrating sieves by
means of an overhead conveyor belt. The fine upper sieves oscillate in opposing push pull
motion to the coarser lower screen. The sieve oscillating frequency of the two double acting
cylinders is set to f = 1 Hz via the quantity of air supplied in load dependent relation. Reversal
takes place in the retracted end position via two roller lever valves. A third single acting cylinder
unclogs the sieves via two cables. The stone sorter is switched on and off by a valve with selector
switch.

Apparatus: Double acting cylinders – 2 Nos., Single acting cylinder, Double pilot 5/2 way
valve – 3 Nos., 3/2-way roller lever valve normally closed – 2 Nos, 5/2 way valve with selector
switch

Working of the circuit: In the initial position, double acting cylinder “A”(upper sieve) and
single acting cylinder “C” (unclogger) assume the retracted end position; the double acting
cylinder “B”(lower sieve) rests in the forward end position. Roller lever valve “1” is actuated.

Step 1-2
After operation of the valve with selector switch final control elements (double pilot 5/2 way
valves) are reversed. Cylinders A and C move forward. Cylinder B retracts and actuates the roller
lever valve.

Step 2-3
Through the actuation of roller lever valve “2”, all final control elements again reverse. Cylinder
“B” moves forward. Cylinder “C” retracts. Cylinder “A” likewise retracts and again actuates the
roller lever valve “1”.

Continuous cycle
As long as the 5/2 way valve with selector switch remains in the switched condition, the motion
sequence will be repeated. If the valve is brought to the initial start position, the system remains
in its initial position at the end of a cycle.