4/24/2024

Chapter 4

MULTI-ACTUATOR CIRCUITS

presented by: Dr. Minh Tuan HO

[email protected]
ME3001 – Hydraulic & Pneumatic Engineering 1

Outlines
1. Introductions

2. Classical / Intuitive Method

❑ Steps

❑ Eliminate of signal conflict

3. Cascade Method

4. Questions

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1. Introductions

 Most of the practical pneumatic circuits use multi cylinders.

 They are operated in specific sequence to carry out the desired
task. Ex: to drill a wooden component, first we need to clamp and
then drill → sequencing of movement of clamp cylinders and drill
cylinder is important.

Common methods

 Five common methods to design multi cylinder pneumatic

circuits:
❑ Classic/ Intuitive method
❑ Cascade method
❑ Step counter method
❑ Karnaugh(–Veitch) method
❑ Combination method
 Cascade and Step counter method are more systematic
methods than classic methods: signal conflict can be
eliminated

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2. Classic / Intuitive Method

 Circuit design is done by use of general knowledge of

pneumatics following the sequence through intuitively.
 Steps include
❑ Write down sequence and draw motion diagrams
❑ Draw in cylinders and control valves
❑ Complete circuits intuitively.

Example: Stamping machine

 In a press shop, stamping

operation to be performed using
a stamping machine.
Stamping cylinder
 Before stamping, the workpiece
must be clamped under
stamping station. Clamping cylinder
 Then stamping tool comes and
performs stamping operation.
 Work piece must be unclamped
only after stamping operation.

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Step 1: Write the statement of the problem

 Let A be the clamping cylinder and B be the stamping

cylinder
 First, cylinder A extends and brings under stamping
station where cylinder B is located.
 Then, cylinder B extends and stamps the job.
 Next, cylinder B retracts.
 Finally, cylinder A returns only cylinder B has retracted
fully.

Step 2: Draw the positional layout

B

Step 3: Represent the control task using notation

 Cylinder A advancing step is designated as A+
 Cylinder A retracting step is designated as A-
 Cylinder B advancing step is designated as B+
 Cylinder B retracting step is designated as B-

Sequence: A+ B+ B- A-

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Step 4: Draw the Displacement–step/time diagram

B+
B

Step 1

Step 5: Analyse input and output signals

Input signals
 Cylinder A:
❑ Limit switch at home position a0
❑ Limit switch at home position a1
 Cylinder B:
Output signals
❑ Limit switch at home position b0  Cylinder A:
❑ Forward motion A+
❑ Limit switch at home position b1
❑ Return motion A-
 Cylinder B:
❑ Forward motion B+
❑ Return motion B-
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Step 6: Link signals with displacement time/step

diagram

Usually, start signal is also required along with a0 signal for

obtaining A+ motion.
1. Ending A+ action generates sensor signal a1, used for B+ motion
2. Ending B+ action generates sensor signal b1, used for B- motion
3. Ending B- action generates sensor signal b0, used for A- motion
4. Ending A- action generates sensor signal a0, used for A+ motion

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Signal flow diagram

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Step 7: Draw the power circuit

 Draw the cylinders A(1.0) and B(2.0)
 Draw the DCVs 1.1 and 2.1 in unactuated conditions and port numbering
 Mark the limit switch positions for cylinders A(1.0) and B(2.0)

Power circuit diagram

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Step 8: Draw the control circuit

 Add sensors with signals to the power circuit

Pneumatic circuit for A+ B+ B- A-

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Step 9: Analysis of pneumatic circuit

1. When the start button is pressed, the signal appears at port 14 of valve
1.1 through limit switch signal a0.
2. Check the other end of DVC 1.1, notice that the signal is also present at
port 12 of valve 1.1 (because b0 is also pressed). This results in signal
conflict and valve 1.1 is unable to move.

Signal conflict at DCV 1.1 15

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Step 9: Analysis of pneumatic circuit

3. Let us assume for time being, b0 is somehow disengaged so that valve
1.1 can switch over and consequently cylinder A can extend (when the
start button is pressed).

After cylinders A, B are extended

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Step 9: Analysis of pneumatic circuit

4. When cylinder A fully extends, it generates a limit switch signal a1,

which is applied to port 14 of the valve 2.1.
5. Check the other end of DVC 2.1, there is no signal, thus no conflict
6. Signal applied to port 14 of the valve 2.1 causes the shifting of DCV 2.1
and cylinder B extends.

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Step 9: Analysis of pneumatic circuit

7. When cylinder B fully extends, it generates a limit switch signal b1,
which is applied to port 12 of DVC 2.1
8. Check the other end of valve 2.1, there is signal at the port 14 (because
a1 is also pressed). This results in signal conflict and DVC 2.1 is unable
to move

Signal conflict at DCV 2.1

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Step 9: Analysis of pneumatic circuit

9. Let us assume for time being, b1 is somehow disengaged so that valve
2.1 can switch over and consequently cylinder B can retract

When cylinder B is reversing B-

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Step 9: Analysis of pneumatic circuit

10. When the cylinder B is fully retracted, it generates a limit switch signal
b0, which is applied to port 12 of DVC 1.1
11. Check the other end of DVC 1.1, there is no signal at port 14 of DVC 1.1,
hence no signal conflict. So DVC 1.1 can switch over and Cylinder A can
retract.

When cylinder A has fully retract A-

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Eliminate of signal conflict

 Various methods are used to solve problem of signal

conflicts in multi cylinder circuits
❑ Idle return roller
❑ Reversing valves ( memory valves)
❑ Modules as combination of valves
 Cascading method uses the revering valves ( also known
group changing valves) and Step counter method uses
modular valves.

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Use of Idle Return Roller / Roller lever valves

công tắc hành trình kiểu bánh xe gạt
 An idle-return roller valve consists of a 3/2 DCV fitted with
an idle return roller mechanism

Two designs of Idle return roller 22

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Use of Idle Return Roller

Drawbacks
 This method is
not reliable
 End position
cannot be sensed
accurately
 Fast control
system cannot be
set up

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3. Cascade Method

 A Bi-stable memory valve or reversing valve can be used to

eliminate signal conflicts.
 Signal conflict is avoided by allowing the signal to be
effective only at times when they are needed.
 Two of the possible designs are possible:
❑ Cascade method
❑ Shift register method

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Example: Stamping machine

 In a press shop, stamping

operation to be performed using
a stamping machine.
Stamping cylinder
 Before stamping, the workpiece
must be clamped under
stamping station. Clamping cylinder
 Then stamping tool comes and
performs stamping operation.
 Work piece must be unclamped
only after stamping operation.

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Step 6: Link signals with displacement time/step

diagram
Usually, start signal is also required along with a0 signal for
obtaining A+ motion.
1. Ending A+ action generates sensor signal a1, used for B+ motion
2. Ending B+ action generates sensor signal b1, used for group
changing
3. Ending B- action generates sensor signal b0, used for A- motion
4. Ending A- action generates sensor signal a0, used for group
changing

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Signal flow diagram

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Step 7: Draw Power circuit

1. Divide the given circuits into groups. Grouping should be done such that
there is no signal conflict.
❑ Do not put A+ and A- in the same group. Similarly, B+ and B- should not
be put in the same group.
❑ In our example, A+ B+ B- A- can be grouped as: group 1 (A+ B+),
group 2 (B- A-)
2. Choose the no of group changing valve = no of groups -1
❑ In our example, we have 2 groups, so we need one group changing valve
3. Connect the group changing valve as follows

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Step 7: Draw Power circuit

4. Arrange the limit switch and start button as given below

4. Draw the power circuit

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Step 8: Draw Control circuit

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Step 9: Analysis of pneumatic circuit

1. Assume that air is available in the line G2 to start with. (Say from last operation)
2. When the start button is pressed, Air supply from Group G2 is directed to line 2 through
actuated limit switch a0. Now the air available in line 2, actuates the Group changing valve
(GCV) to switch over to position I. This switching of the GCV causes air supply to change
from G2 to G1.
3. Now the air is available in line G1. The air supply from group G1 is directed to port 14 of
the valve 1.1. As there is no possibility of signal conflict here, valve 1.1 switches over
causing the A+ action.
4. Sensor a1 is actuated as the result of A+ action, allowing the air supply from the Group G1
to reach to line 1 through a1. Now the air available reaches port 14 of valve 2.1. As there is
no possibility of signal conflict here, valve 2.1 switches over, causing B+ action
automatically.
5. Sensor b1 is actuated as result of B+ action, allowing the air supply in line 3. Air from line
3 allows the air to reach port 12 of Group changing valve (also called reversing valve). As a
result, the Group changing valve switches over, causing the group supply to change from
G1 to G2.
6. Now the air is available in G2. Air from G2 acts on port 12 of the Valve 2.1. As there is no
possibility of signal conflict here, valve 2.1 switches over, causing B- action automatically.
7. Sensor is actuated as the result of B- action. Now the air is available in line 4.Air from line 4
reach port 12 of the valve 1.1 , As there is no possibility of signal conflict here, valve 2.1
switches over , causing A- action automatically.
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Cascade system

The cascade system provides a straightforward method of

designing any sequential circuit. Following are the important
points to note
 Present : the system must be set to the last group for start-
up
 Pressure drop : Because the air supply is cascaded, a large
circuit can suffer from more pressure drop.
 Cost : Costly due to additional reversing valves and other
hardware.

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4. Objective Type Questions

1. Design of circuits using intuitive method is …… time
consuming compared to step counter method.
2. When hardware costs are not important, but circuit design
time must be minimal, then ….. Method of the circuit design
is used.
3. Where the hardware costs are paramount, then ….. circuit
methods are used.
4. When absolute fool proofing of circuits is required, ……
circuit methods are used.
5. …… are used to sense the end position of cylinder
movements

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State True or False

1. We have to draw all valves in their de-actuated ,
unpressurised rest position as in electrical switching
components
2. In order to gain fully controlled sequence of all cylinders in
a program , it is essential to install end position sensors at
all movements end position.
3. 4/2 or 5/2 double piloted valves are free from signal
overlaps.
4. Step counter method is absolutely free from signal conflicts
5. Time delay and pressure delay functions cannot be used in
multicylinder circuit design

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Review Questions
1. Explain how signal conflict occurs using an example
2. What is the effect of signal conflict in multi actuator circuit design
3. What are the different ways to eliminate signal conflict in multi actuator circuit
design
4. Explain the step displacement diagram for A+B+B-A- sequence.
5. List few disadvantages of using idle return rollers for overcoming signal conflicts
6. Explain the principle of cascade method with a suitable sequence example
7. Briefly explain the principles of step counter method with a suitable example
8. Draw a group changing cascade circuit for two groups, three groups, four
groups and five groups.
9. Explain with the help of neat sketch the construction and working of pressure
sequence valve
10. What are the different ways to sense the end position and movement of
cylinders

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References
1. A. Esposito, Fluid power with applications, 7th edition,
Pearson, 2014
2. P. Chapple, Principle of hydraulic systems design, 2nd
edition, Momentum Press, 2015

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