MECH610/PNEUMATICS & ELECTRO-PNEUMATICS

Module 4 (LEC) – Development of Pneumatic Circuits using

Non-Return Valves and Flow-Control Valves

Learning Outcomes:
At the end of this module, students are expected to:
C1. Demonstrate critical knowledge and understanding of core pneumatic and/or
electro-pneumatic theories and concepts.
C2. Critically evaluate problems and provide appropriate solutions to real-life
production problems involving pneumatic and/or electro-pneumatic systems.
C3. Apply pneumatic and/or electro-pneumatic standards and design to produce
solution that meet given mechatronic system specification.

Specifically,
✓ Dual-pressure Valve and the logic AND function
✓ Shuttle Valve and the logic OR function
✓ Flow-Control Valves

Introduction
Non-return valves permit flow of air in one direction only, while other direction blocks the
air flow. Mostly the valves are designed in such a way that the check is additionally
loaded by the downstream air pressure, thus supporting the non-return action.
Valve is a device controlling the direction, pressure and rate of flow of air delivered by a
compressor to the actuator. Valves are classified into four principal groups according to
their functions:

✓ Directional control valves

✓ Non-return valves
✓ Flow control valves
 ✓ Pressure control valves

DIRECTIONAL CONTROL VALVE (DCV)

DCVs re used to control the direction of air flow in the pneumatic circuit from input port
to output ports by generating, relieving and redirecting the air signals. Types of
directional control valves:
1. Based on construction element used
✓ Ball Seat
✓ Disc Seat
✓ Diaphragm
2. Based on the number of ports
✓ Two-way
Three-way
✓ Four-way
3. Based on the methods of actuation
✓ Mechanical
✓ Electrical
✓ Pneumatic

The types of directional control valves:

• Check valve

• Pilot operated check valve

• Three-way and four-way valves

• Manually actuated valve

• Pilot actuated valve

• Solenoid actuated valve

• Shuttle valve

One Way Flow Control Valve:

• A check valve, non-return valve, reflux valve, retention valve, foot valve, or one-
way valve is a valve that normally allows fluid (liquid or gas) to flow through it in only
one direction.
• This valve is also called as the Throttle Relief Valve.
•Generally used for Speed Control of Cylinder and is installed in the working pressure
line, between the final control valve and the cylinder ports.
•Controls the flow rate in one direction only & allows free flow in the opposite direction.
•Check valves are two-port valves, meaning they have two openings in the body, one
for fluid to enter and the other for fluid to leave.

Figure11. One Way Flow Control Valve

▪ Two ways of throttling using one-way flow control valves:

1)

Figure12. One Way Flow Control Valve : flow is from (P) to (A)
 If the flow is from (P) to (A), the check valve stops the flow then passes through the
throttle valve.
The cross-section of the throttle is adjustable via a regulator screw.
2)

Figure13. One Way Flow Control Valve : flow is from (A) to (P)

If the flow is in the opposite direction from (A) to (P), the check valve permits the flow
freely from (1) to (2).

▪ Types of Flow control double acting cylinders

1) Supply Air Throttling

Figure14. One Way Flow Control Valve installed supply air throttling

•In the case of supply air throttling, the one-way flow control valves are installed such that
air being fed to the cylinder is restricted.
• Exhaust air can escape freely via the 5/2 way valve.
•Supply air throttling is used for single acting cylinders and small volume double acting
cylinders.

2) Exhaust Air Throttling

Figure15. One Way Flow Control Valve installed exhaust air throttling

• In the case of exhaust air throttling, supply air flows freely to the cylinder and the flow
control in the exhaust line resists the escaping air.
The piston is held between two air cushions.
• Exhaust air throttling should always be used for large double acting cylinders with long
strokes, and when the loads are not constant.

Types of Non-return Valves

✓ Check Valve
✓ Restrictor Check Valve
✓ Shuttle Valve
✓ Two-pressure Valve
✓ Quick exhaust Valve
Shuttle Valve/OR Valve
Shuttle valves are also called double check valves and are used when the control is
required from more than one power sources. Shuttle valves are used to select the
higher of two inputs pressure automatically and connect the output port. This valve is
also known as OR valve.

Figure1. Shuttle/OR Valve

OR valve consists of two inlet ports and one outlet port. As long as the pressure in the
right inlet port is higher than the left, the spool closes the left port and air from the right
port is connected to an outlet. If the pressure on the left side is higher than the right
side, then air from the left is connected to an outlet.

OR pneumatic logic has two or more inputs and one output. The output is OFF only if all
the inputs are off. All combinations of inputs and outputs can be shown in a “truth table”.
A two-input OR elements with inputs X and Y and output A and its truth table is given in
table 1.

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 X Y A
0 0 0
0 1 1
1 0 1
1 1 1
Figure2. Logic OR Truth Table

In below pneumatic circuit, two hand operated valves that can be at different positions
are inputs to extend the cylinder. These two inputs can be connected using a shuttle
valve which can cause extension if either or both valves are actuated.

Figure3. Controlling a cylinder with two input elements

OR/shuttle valves can be cascaded in case more than two inputs are required to extend
the cylinder.

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 Figure4. Controlling a cylinder with three input elements

Two Pressure Valve/Dual Pressure Valve/AND Valve

This valve is a pneumatic AND valve which requires two pressurized inputs to allow an
output from itself. The cross-sectional view of a two-pressure valve in two positions is
shown below. This valve has two inputs 1 and 3 and one output 2. If the compressed air
is applied to either 1 or 3, the spool moves to block the flow, and no signal appears at
output 2. If signals are applied to both input ports, the compressed air flows through the
valve, and the signal appears at output 2.

Figure5. Two Pressure /Dual Pressure/AND Valve

The two pressure or dual pressure valve can be used as AND valve. AND pneumatic
logic has two or more inputs and one output. The output is ON only if all the inputs are
ON. All combinations of input and output can be shown in the truth table below.

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 X Y A
0 0 0
0 1 0
1 0 0
1 1 1
Figure6. Logic AND Truth Table

The dual pressure valve circuit is equivalent to the two input signaling devices in series
as shown in the pneumatic circuit below. The signal output is passed all the way
through only if both signal elements are operated.

Figure7. Sample Circuit Diagram with AND application

Quick Exhaust Valve

A quick exhaust valve is a typical shuttle valve that can also exhaust the cylinder air
quickly to the atmosphere. In many applications especially with a single-acting cylinder,
it is a common practice to increase the piston speed during retraction of the cylinder to
save the cycle time. To increase the piston speed, the resistance to the flow of the
exhausting air should be reduced. This can be done by expelling the exhausting air to
the atmosphere quickly by using the quick exhaust valve.

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 Figure8. Quick Exhaust Valve
Quick exhaust valve consist of a movable disc or a flexible ring, an inlet port (1),
cylinder port (2) and exhaust port (3). When the air flowing from the directional control
valve is applied to the inlet port, the disc blocks the exhaust port where the compressed
air passes from port 1 to 2. When the return air from cylinder enters the exhaust valve, it
pushes the disc to cover the inlet port and return air quickly exhausted to the
atmosphere.

Figure9. Circuit Diagram with quick exhaust valve

Flow Control Valve

A flow control valve regulates the rate of air flow that controls the speed of the actuator.
Flow control valves are used in the pneumatic circuit to control the rate of flow of the
compressed air from one part of the circuit to the other. Their function is to regulate the
amount of compressed air passing through a valve using a metering orifice.

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Two types of flow control valves
✓ Throttle valve
✓ One-way flow control valve

Throttle valve consists of an orifice whose area can be controlled externally adjustable
needle the throttle valve is also called a needle valve or a restriction valve.

One-way flow control valve is also called a throttle relief valve or a throttle check valve.
The air flow is throttled in one direction only. A check valve blocks the flow of air in the
bypass leg and the air can flow only through the regulated cross-section. In the opposite
direction, the air can flow freely through the opened check valve. These valves are used
for speed regulation and if possible, should be mounted directly on the cylinder.

Figure10. Throttle Valve and One-way Flow Control Valve

References and Supplementary Materials:

Jagadeesha T., Hydraulics and Pnuematics. 2015
P. Croser and F. Ebel, Pneumatics (FESTO). 2002

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Online Supplementary Reading Materials:

https://www.researchgate.net/publication/326701415_DEVELOPMENT_OF_PNEUMAT
IC_CONTROL_SYSTEMS
http://www.t4.ie/Professional_Development/RD9_Technology/Pneumatics/RD9%20Pne
umatics.pdf

Online Instructional Videos:

https://www.youtube.com/watch?v=uAvOQh43Erohttps://www.youtube.com/watch?v=T
n3bsiQx1Ug