Pneumatics and Hydraulics

Lecture 11: Pneumatic system design and

development
Dr. Ahmad Al-Mahasneh
Symbols And Standards In Pneumatics

•The development of pneumatic systems is assisted by a uniform

approach to the representation of the elements and the circuits.
•The symbols used 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.
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 symbols for fluidic equipment and systems".
Symbols And Standards In Pneumatics
Symbols And Standards In Pneumatics
Symbols And Standards In Pneumatics
Symbols And Standards In Pneumatics
Symbols And Standards In Pneumatics
Symbols And Standards In Pneumatics
Symbols And Standards In Pneumatics
Symbols And Standards In Pneumatics
Symbols And Standards In Pneumatics:
Control valves
Symbols And Standards In Pneumatics
:Control valves
Symbols And Standards In Pneumatics
:Control valves
Symbols And Standards In Pneumatics:
Control valves
Symbols And Standards In Pneumatics:
Control valves
Symbols And Standards In Pneumatics
:Control valves
Symbols And Standards In Pneumatics
:Control valves
Symbols And Standards In Pneumatics
:Control valves
Symbols And Standards In Pneumatics
:Control valves
Symbols And Standards In Pneumatics: flow
lines and connections
Symbols And Standards In Pneumatics: flow
lines and connections
Symbols And Standards In Pneumatics: flow
lines and connections
Symbols And Standards In Pneumatics: flow
lines and connections
Symbols And Standards In Pneumatics:
mechanical components
Symbols And Standards In Pneumatics:
mechanical components
Symbols And Standards In Pneumatics:
electrical control
Control valves
Control valves
Measuring instruments
 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 labeling.
Comprehensive documentation is required including most of the following:
• Function diagram
• Circuit diagram
• Description of the operation of the system
• Technical data on the components 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)
Design of the circuit diagram
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 parts (service
unit, shut-off valve, various distributor connections) are shown on a
separate page of the drawing for the purpose of simplification
Design of the circuit diagram
Design of the circuit diagram
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.
•In this case, the actuated switching position must be connected.
 Designation by numbers

•With this type of designation, elements are divided into groups.

Group 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.
 Designation by Letters

•This type of designation is used primarily for a systematic

development of circuit diagrams. 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.
The piston rod will return provided the manual actuators have been
released.
 Example:
• Solution:
•The roller lever valve 1S3 is positioned as a limit switch in the forward
end position of the cylinder.
•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 and contains several working 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.
Example:
Summary
• 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 elements in the initial position of the control. Identify actuated
elements by a cam.
• Draw pipelines straight without cross-over wherever possible.
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-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.
Positional sketch
Motion diagram

• The displacement-step diagram and the displacement-time diagram

are used for motion sequences. The displacement-step 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, they are shown in the same way
and are drawn one below the other. Their interrelation can be seen
by comparing the steps.
Motion 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.
 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 time.
• The switching time is not taken into account.
• The control diagram in the following figure
shows the statuses of the control components
(1V for cylinder 1A and 2V for cy1inder 2A)
and the status of the limit switch 1S1 fitted at
the front end position of the cylinder 1A.
Function diagram

•The function diagram is a combination

of the motion diagram and the control
chart.
•The lines representing the individual
states are referred to as function lines.
 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 in status occurs, dependent on this signal.
• 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 lines.
• Several signal outputs effect the same change 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.
Representation of signal lines Representation of input elements
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, 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.