CHAPTER 10

Pneumatics Components

10.1 Filter
10.2 Regulator
10.3 Lubrication
10.4 Muffler
10.5 Valves
10.6 Actuator
10.7 Other related components and accessories
10.0 Introduction
➢ Fluid conditioning
 Maximum pneumatic system operating efficiency is achieved when system compressed
air is:
I. Consistently clean
II. Free from moisture
III. At a relatively uniform temperature

➢ Intercoolers
 Intake air temperature usually depends on the location of the compressor air intake
 Intercoolers and aftercoolers are used to remove heat of compression
 Intercoolers cool compressed air between the stages of a multiple-stage compressor
 Aftercoolers cool the air after the air has been compressed
 Either air or water can be used as the cooling medium in these devices
➢ Airdryers
Remove virtually all moisture from compressed air
The air coming out of this component is basically free of moisture – dry air.
It is installed after air-cooler.
3 basic types available:
I. Chemical – using chemical reaction to remove moisture (chalk, calcium
chloride)
II. Adsorption – using material such as silica gel.
III. Refrigeration – using chiller dryers unit, just like in a air condition system.

Figure 1: Typical FRL Unit

 10.1 Filter
➢ Pneumatic systems need to carefully filter the air taken into the compressor intake
to extend the service life of
i. Compressor
ii. Other system components
➢ RL air filter removes:
i. Airborne dirt remaining in the atmospheric air compressed in the system
ii. Rust and scale from the interior of the distribution lines
iii. Liquid water that has condensed in the drop line
iv. Atomized oil from the operating compressor
➢ Filters used on the intake line of pneumatic compressors may be
i. Dry element
ii. Oil wetted
iii. Oil bath Figure 2: Typical FRL Air Filter

➢ The filter used is based on the type of compressor, atmospheric conditions, and
the final use of the compressed air
10.2 Regulator

 The pressure regulator in an FRL unit reduces system distribution line pressure to
the level needed by workstation tools and circuit actuators
 Unit is also necessary as air pressure in the distribution line fluctuates due to
varying air demands and the characteristics of compressor-capacity control
 Several regulator designs are available for use in a pneumatic system
i. Direct-operated regulator
ii. Basic, diaphragm-chamber regulator
iii. Relieving-type regulator
iv. Balanced-poppet valve regulator
v. Pilot-operated regulator
1. Direct-operated

 Regulators commonly use a flexible

diaphragm to sense outlet line pressure
and provide the balancing force needed
to control airflow through a poppet
valve
 Only sufficient airflow to maintain the
selected workstation pressure is allowed
to pass through the poppet valve to the
outlet port of the regulator
 2. Basic, diaphragm-chamber
 Regulators have a diaphragm-control chamber to
separate the regulator side of the diaphragm
from direct contact with distribution system air

➢ Sensing orifice connects the control chamber and

outlet port

➢ This dampens the reaction of the diaphragm,

providing more sensitive and efficient workstation
pressure control

➢ Protects diaphragm from contaminants

3. Relieving-type regulator

 Some regulators contain a venting orifice

located in the center of the diaphragm

➢ Prevents pressure increase in the outlet

port beyond the regulator pressure setting

➢ The relieving action automatically bleeds air

from the outlet port to the atmosphere

➢ This design feature allows the regulator to

act like a small relief valve
 4. Balanced-poppet valve regulator

 Balanced-poppet valve regulators have a

design that subjects both ends of the valve
poppet to equal air pressure

➢ Allows the valve to be more accurately

positioned

➢ Produces better pressure control and

improved response to system load
variations
 5. Pilot-operated regulator
 Pilot-operated regulators have a sealed
pilot-air chamber in place of a control
spring and adjustment screw

➢A second, small, remotely located

regulator is used to control air
pressure in the pilot-air chamber

➢ The air pressure in the pilot-air chamber

acts as an air spring to establish the
setting of the pilot-operated regulator
 Factors to consider when selecting a system regulator are:
Regulator style
Pressure range
Airflow range
Conductor connection size
10.3 Lubricator

 The lubricator in an FRL (filter, regulator, and

lubricator) unit meters oil into pressurized
system air at the workstation

 This provides lubrication for system valves,

actuators, and air-powered tools

 Rapidly moving system air passing through a

lubricator breaks up droplets of oil, forming a
mist or fog.

 This mist is transported through the

workstation lines to system components
10.4 Muffler
➢ The increased use of compressed air in industry has
created a noise problem.
➢ Noises generated by pneumatic systems are high-
intensity energy, much of it in the same frequency
ranges of a normal conversation.
➢ Excessive exposure to those noises can cause a loss
of hearing without noticeable pain or discomfort.
Exposure also causes fatigue and lower production.
➢ The noise problem can be solved by installing a
Muffler
muffler (exhaust silencer) at each exhaust port.
➢ A muffler (exhaust silencer) is used to control the
noise caused by rapidly exhausting airstream flowing
into the atmosphere.
 10.5 Valves
➢ Control valves are used to establish the level of force and type of motion needed to operate a machine.
These valves control:
i. Air pressure
ii. Direction of airflow
iii. Rate of airflow
1. Pressure control valves:
i. Limit maximum system pressure
ii. Regulate the force or torque an actuator generates
2. Directional control valves
✓ Control airflow direction to establish the direction of actuator movement.
3. Flow control valves
✓ Regulate the rate of airflow to control actuator operating speed.
Examples of directional valves normally used in pneumatic systems are:

1. Check valve
 Allows airflow in one direction only.

Figure: Check Valve

2. Shuttle valve
 Selects (automatically) the higher of two input pressures and connects that
pressure to the output while blocking the lower pressure.

Figure : Shuttle Valve

3. Three-way directional control valve
 Pressurize a single-acting cylinder during extension.
 Vent air during retraction to allow the cylinder to be returned to the initial position by
external forces

Figure : Three-way (push button) DCV

4. Four-way directional control valve
 Four-way directional control valves direct compressed air to power a cylinder
during both extension and retraction.
 They also power air motors during both directions of rotation.
 Four-way directional control valves are available in four-port and five-port
configurations
➢ A common exhaust is used in the four-port design
➢ The five-port design uses separate exhaust ports for the extension and retraction positions of
the valve

 Four-way directional control valves are normally available providing two or three
positions of operation
➢ Two-position valves power an actuator in one direction in the first position and in the opposite
direction in the second position
➢ Three-position valves provide additional operating options using the middle valve position
Figure : four-way DCV Figure : 2 or 3 position four-way DCV
 Three center position configurations are commonly available for pneumatic three
position, five-port valves
 Blocked center
 Open center
 Pressure center

Figure : Blocked center Figure : Open center Figure: Pressure center

Examples of flow control valve normally used in pneumatic
systems are:

1. Needle (throttle) valves

Figure : Needle valve with integral check valve

10.6 Pneumatic Actuators
 Pneumatic systems convert the potential energy of compressed air into force and
movement using:
➢ Cylinders
➢ Motors

Cylinders Motors

• Provide straight-line movement and force • Convert the potential energy of compressed
for use in mechanically operated equipment: air into torque and rotary movement:
• Often called linear actuators • Often called rotary actuators
• Force generated is controlled by system • Torque depends on air pressure and the
pressure internal structure of the motor
• Speed of movement is determined by the • Operating speed is determined by the
volume of air allowed to enter the unit internal displacement of the motor per
revolution and the volume of compressed
air passing through the motor
Pneumatic Cylinders

 The basic structure of pneumatic cylinders is very similar to those used in hydraulic
systems:
➢ Lower system operating pressures allow the use of lighter materials in pneumatic-system
components
➢ Water vapor present in compressed air requires the use of corrosion-resistant materials or coatings
for component parts

Figure : Typical Pneumatic Cylinder Figure : Basic pneumatic cylinder construction

 Pneumatic cylinders may be single or double acting
 The operating principles of single-acting and double-acting pneumatic cylinders
are basically the same as the cylinders designed for hydraulic applications
 Two factors are basic to determining required actuator size:
➢ Cylinder force output
➢ Absolute air consumption required to produce desired system performance
Air motors
 Air motors are available in many designs for example.
➢ Vane
➢ Piston

 The vane air motor is the most common design. Vane motors can be found in hand
tools and large, stationary installations.
 Piston air motors are most often found in installations requiring higher horsepower
output.
 They are available in both axial and radial piston designs.

 Three performance factors that make piston air-motors desirable in many

pneumatic system applications are:
 High power output
 High starting torque
 Accurate speed control
Tutorial Questions
1. List down the components used for fluid conditioning in a pneumatic system.
2. Describe the function of an air filter.
3. Describe the function of an air regulator
4. Why would a lubricator be used in a pneumatic system?
5. Describe in brief the intercooler and air dryer components