Federal TVET Institute

Department of Electrical/Electronic Technology

Chapter 1: Pneumatic systems

8. Development of pneumatic control system

The development of the control system solution requires that the problem is defined clearly. Problems description
are in statement form. There are many ways of representing the problem in a descriptive or graphical form. The
methods representing control problem include:

 Positional sketch
 Displacement-step diagram
 Control chart
 Function diagram
 Function chart
 Circuit diagram

Problem description: Problem description of a lifting device could be stated as:

A lifting device transfers workpiece from one roller conveyor to another at different height. Drive 1A lifts the
workpiece from the lower roller conveyor. Drive 2A pushes the workpiece onto the upper roller conveyor.

Positional sketch: The positional sketch shows the

relationship between the actual machine fixtures. The
actuators are shown in the correct orientation.

It is 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. An example is shown in Figure.

Displacement-step diagram: The displacement-step or

– time diagram are used for representing motion or
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 their steps. An example is
shown in figure.

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 5 is equivalent to step 1.

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EET 337 Pneumatic and Hydraulic Systems
Yohannes H/m
 Federal TVET Institute
Department of Electrical/Electronic Technology

Chapter 1: Pneumatic systems

Control chart: In the control chart, the switching status

of the control element is represented in relation to the
steps or the time.

The control diagram shown in Figure shows the status

of the control components (1V for cylinder 1A and 2V
for cylinder 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.

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 the signal outputs are present. Representation
of signal lines are shown in Figure below.

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EET 337 Pneumatic and Hydraulic Systems
Yohannes H/m
 Federal TVET Institute
Department of Electrical/Electronic Technology

Chapter 1: Pneumatic systems

Representation of input elements are shown below

The designation of the individual input elements are entered at the out-put point of the respective signal line. An
example of a function diagram (displacement-step diagram with signal lines) is shown in Figure below.

The diagram above 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 switches 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.

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EET 337 Pneumatic and Hydraulic Systems
Yohannes H/m
 Federal TVET Institute
Department of Electrical/Electronic Technology

Chapter 1: Pneumatic systems

Abbreviated notation: It is another possibility of representing motion sequences. In this case, the cylinder
designations 1A, 2A, etc. are used in the sequence. The signal for advancing is designed using a ‘+’ and the signal
for retracting using a ‘-‘.
 The sequence is to be read as follows: Cylinder 1A advances, cylinder 2A advances,
cylinder 2A retracts, then cylinder 1A retracts. Sequential movements are written consecutively.

 The sequence is to be read as: Cylinder 1A advances, cylinder 2A advances and

cylinder 1A retracts, cylinder 2A retracts. Simultaneous movements are written vertically.

Circuit diagram: The circuit diagram shows signal flow and the relation between components and their connections.
There is no mechanical layout representation with the circuit diagram. An example of a circuit diagram is shown in
Figure below.

The circuit is drawn with the energy flow from bottom to the top. The various levels of a circuit includes the energy
source, signal inputs, signal processing, control elements and the actuators. The position of the limit valves are
marked at the actuator. Components and lines are identified by the component numbering system and port
connection numbers. These allow cross references to the components on the actual machine and make the circuit
readable.

In summary

In development of pneumatic systems with multiple cylinder circuits, a clear definition of the problem is important.
The representation of the desired motion of all actuators is described using the displacement-step diagram. The
special conditions for the start of the sequence must also be defined.

If the motion diagram and auxiliary conditions have been clearly defined, drawing of the circuit diagram can
commence.

And note that, it is essential to avoid overlapping signals as it prevents the circuit to operate. By an overlapping
signal, we understand signals applied simultaneously at the two control ports of double pilot valve.

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EET 337 Pneumatic and Hydraulic Systems
Yohannes H/m
 Federal TVET Institute
Department of Electrical/Electronic Technology

Chapter 1: Pneumatic systems

9. Advanced pneumatic components

The components of pneumatic systems especially electropneumatic control systems have been constantly improved
in recent years. The most important objective in all development of components, whether of new or existing
products, are these:
 Reduction of overall costs (primarily focused at reducing the cost of project planning, installation,
commissioning and maintenance)
 Improvement of performance data (for example reducing cycle time by increasing motion speeds,
reducing mounting space and weight, integration of additional functions such as linear guides)
 Opening up of new application area (with the development of low cost new components)

9.1. Pneumatic actuators

a) Linear cylinders

Alongside standard cylinders, which are retaining their importance as cost effective and versatile component,
special purpose cylinders are increasingly growing in significance. On these cylinders additional components such
as guides and supports are frequently mounted directly on their housing. For example the piston rod of a standard
cylinder rotates slightly as there is no guide to prevent this. Therefore it is not possible to directly mount a tool, e.g.,
a cutting blade. For this kind of application where no considerable torque is exercised on the tool, a cylinder with
non-rotating rod can be used. In general special cylinders offers many advantages such as smaller installation space
and reduced displaced masses. The reduction in outlay for materials, planning and assembly results in a noticeable
lowering of costs.

Double rod cylinder

It is controlled by alternating the compressed air input. The cushioning cab be

adjusted by with two adjustment screw.
It is stronger against side load as it has two bearings at the widest distance possible.

Twin rod cylinder with a trestle

The twin cylinder has two in and out piston rod that move in parallel and that are
coupled by a trestle.
Has high latera load resistance and high rotating accuracy. These compact dual rod
cylinders are of high precision and ideal for pick and place operations

Double twin rod cylinder with two trestle.

The twin cylinder has two in and out piston rod that move in parallel and that
are coupled by two trestle at each end.

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EET 337 Pneumatic and Hydraulic Systems
Yohannes H/m
 Federal TVET Institute
Department of Electrical/Electronic Technology

Chapter 1: Pneumatic systems

Multi-position cylinder

The two end positions of a standard cylinder provide two fixed positions. If more than two positions are required a
multi-position cylinder made from a combination of two or more double acting cylinders may be used. There are
two principles

Three position: By connecting two cylinders of same piston diameter but different maximum stroke in sequence,
three piston position can be realized. From first stop position the third stop can be reached either directly or via the
intermediate stop. Note that the max stroke of the second piston must be larger than the preceding one. The short
max stroke is half of the other max stroke. When moving back an intermediate stop requires a particular control.

Four position and more: Mounting two independent cylinders together back to back allows four different position,
but the cylinder cannot be fixed. A combination of three cylinders of different stroke length gives 8 positions, one
with four 16, but a rather exotic structure is required and the movement, when cylinders run in opposite directions,
is very unstable.

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EET 337 Pneumatic and Hydraulic Systems
Yohannes H/m
 Federal TVET Institute
Department of Electrical/Electronic Technology

Chapter 1: Pneumatic systems

Roadless cylinder

A conventional cylinder of say 500mm stroke may have an overall out stroked dimension of 1100mm. A rode less
cylinder of the same stroke can be installed in a much shorter space of approximately 600 mm. It has particular
advantages when very long stroke are required. There are two types depending of the coupling between piston and
carriage: With magnetic coupling and with mechanical coupling.

Linear drive with shape fitting adapter (mechanical coupling and guided): The sledge of the double acting
cylinder is controlled by alternating the compressed air input. These types of linear drives conveys forces by means
of a shape-fitting piston-sledge construction. The slit cylinder prevents the torsion of the slider. As it excludes the
risk of disconnection of the carrier from the piston under dynamic shocks, it used for lifting or moving heavier
loads.

Linear drive with solenoid coupling (magnetic coupling): It uses magnetic coupling between piston and carriage.
It has unguided and guided. Figure below shows the unguided type. Its disadvantage is with dynamic shocks a
separation of the carriage from the piston is possible. Vertical movements are therefore not recommended.

The problem of side load can be solved with the guided type. A typical one is shown in Figure below. The sliding
of the piston in the double rod (guided) cylinder is controlled by a reciprocal input of compressed air.

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EET 337 Pneumatic and Hydraulic Systems
Yohannes H/m
 Federal TVET Institute
Department of Electrical/Electronic Technology

Chapter 1: Pneumatic systems

b) Rotary actuators

Semi-rotary actuator: Pneumatic semi-rotary drives are used

wherever a rotational or swivel motion is required. The standard
angles of rotation are 900 and 1800.

Air motor: Transforms pneumatic energy into mechanical energy

c) Rotary/linear actuators

It is an assembly of a linear cylinder with a rotary actuator attached to the shaft. With the rotating arm equipped
with a gripper or vacuum pad the actuator can pick up work pieces and deposit them to another location after rotating
the arm. This gives a complete “pick and place” unit for materials handling as shown in the figure below.

The drive can be mounted in different ways, for example with a flange in the end face or with slot nets which can
be inserted in the linear position profile. If necessary the power for the gripper or suction cup can be supplied
through the hollow piston road.

d) Grippers and suction cup

Pneumatic grippers

Pneumatic grippers are used Various types

for manipulating work pieces.  Parallel gripper
The gripper is not normally  Angle gripper
used as shown. Handling  Radial
―tools‖ are machined and  Three point
attached to the gripper.

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EET 337 Pneumatic and Hydraulic Systems
Yohannes H/m
 Federal TVET Institute
Department of Electrical/Electronic Technology

Chapter 1: Pneumatic systems

Vacuum suction nozzle/cup

They are used for handling large workpieces (such as packages),

flexible parts (such as foils) or parts with sensitive surfaces (such as
optical lenses).
The vacuum suction nozzle produce its vacuum ejector principle. As
a compressed air flows from port 1 to port 3, a vacuum is created at
the port 2 to which a sucker can be connected to suck in objects.

9.2. Sensors

Ring/reflex sensor: The ring sensor is a non-contact pneumatic signal output

module. It is supplied low pressure (1.5 to 3 psi / 0.1 to 0.2 bar) at connection
1. If, due to an object, the entering air is disturbed a low pressure signal will
be put out by connection 2 (≥ 0.007 psi / 0.5 mbar).

To simulate an object in the air flow as presented above simply click on the
component during FluidSIM simulation mode. This signal pressure is then
converted to a higher pressure by amplifiers.

Pneumatic proximity switch, magnet/solenoid operated: A permanent 2

solenoid found on the piston of a cylinder triggers the control signal of
3/2 way valve. The flow passes freely from 1 to 2. It uses magnetic
1 3
measuring principle

9.3. Processing valves

Adjustable vacuum actuating valve
It is employed through the conversion of vacuum signal. As soon as 2

the vacuum reaches the adjustable value at connection 12, the

attached valve body is switched.
3

12 1

Low pressure amplifier unit 2 compartment

Each of the two double-level low pressure amplifier units have the
function of a 3/2 way directional valve that is normally closed. The
signal at connection 12 is raised to a highest boost through the use
2
of a double-level amplifier and put out by connection 2. 12

12v 1 3

Pneumatic counter
The counter registers pneumatic signals starting at a predetermined
number and counting backwards. If zero is reached, the counter
releases an output signal. This output signal continuous until the
counter is reset either by hand or from a signal at connection 10.
2

3
12
1 10

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EET 337 Pneumatic and Hydraulic Systems
Yohannes H/m
 Federal TVET Institute
Department of Electrical/Electronic Technology

Chapter 1: Pneumatic systems

Stepper motor module, type TAA and TAB

They are made up of a memory unit (3/2 way valve), and AND and an OR component, a viewable announcement
and an auxiliary manual operation.

The valve ports are identified by letters:

 P=Supply port
 A1,A2,A3,A4=Outputs
 X1,X2,X3,X4=Acknowledgements
 L=Reset(clear)
 Yn+1=Set: Output
 Yn=Set: Input
 Zn=Reset: Output
 Zn+1 = Reset: Input

This unit shown below consists of three TAA and one TAB stepper module which are screwed on to an assembly
base, which is equipped with the required straight push-in fittings.

A1

A1

Yn Y n+1

Yn Yn +1

P P
P P
Zn Zn Zn+1
Zn + 1
L L L
L

X1 X1

In the case of module type TAB, an OR gate is positioned upstream of the Yn inlet of the double pilot valve. If a
signal is applied at Yn or L, the valve is reversed and a signal appears at outlet A. In addition, this signal also resets
the preceding stepper module, the visual indicator and the AND gate is supplied with pressure. When the
acknowledgement signal reaches X, the AND flow is released and the signal Yn+1 appears. This signal is also
maintained if the entire sequencer is reset at L and can thus be used for a renewed start. When the sequencer chain
is started, the module is reset externally at port Z via the reset signal Zn+1 of the first module of the sequencer.

With the TAA modules, an OR gate is connected upstream of port Z in the double pilot valve. This is why, in this
case, the double pilot valve is returned via a signal at Zn+1 from the following stepper.

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EET 337 Pneumatic and Hydraulic Systems
Yohannes H/m