Chapter 3

ELECTROPNEUMATIC
CIRCUIT DESIGN
 • Electro-pneumatic control consists of electrical
control systems operating pneumatic power
systems. In this solenoid valves are used as
interface between the electrical and pneumatic
systems. Devices like limit switches and proximity
sensors are used as feedback elements.
• Electro Pneumatic control integrates pneumatic
and electrical technologies, is more widely used for
Introduction large applications. In Electro Pneumatics, the signal
medium is the electrical signal either AC or DC
source is used. Working medium is compressed air.
Operating voltages from around 12 V to 220 Volts
are often used. The final control valve is activated
by solenoid actuation
The resetting of the valve is either by spring [single Solenoid]or using another
solenoid [Double solenoid Valve] . More often the valve actuation/reset is achieved
by pilot assisted solenoid actuation to reduce the size and cost of the valve

Control of Electro Pneumatic system is carried out either using combination of

Relays and Contactors or with the help of Programmable Logic Controllers [PLC].

A Relay is often is used toconvert signal input from sensors and switches to number
of output signals [ either normally closed or normally open] .Signal processing can
be easily achieved using relay and contactor combinations
In Electro pneumatic controls, mainly three
important steps are involved:

• Signal input devices -Signal generation such as

switches and contactor, Various types of contact
and proximity sensors
• Signal Processing – Use of combination of
Contactors of Relay or using Programmable Logic
Controllers
• Signal Out puts – Out puts obtained after
processing are used for activation of solenoids,
indicators or audible alarms
 • Manually actuated push button switches
• Limit switches
SEVEN BASIC •
•
Pressure switches
Solenoids
ELECTRICAL • Relays
•
DEVICES •
Timers
Temperature switches

Other devices used in electro pneumatics are

• Proximity sensors
• Electric counters
 Push buttons are of two types

Momentary push Maintained contact or

Push button detent push button
button
switches
Momentary push buttons return to their
unactuated position when they are released.
Maintained (or mechanically latched) push
buttons has a latching mechanism to hold it in
the selected position.
The contact of the
push buttons,
distinguished
according to their
functions,

• Normally open (NO)

type
• Normally closed
(NC) type
• Change over (CO)
type.
Limit switches

Two types classification of Limit switches

• Lever actuated contacts
• Spring loaded contacts
 Solenoids

Electrically actuated directional control valves form the interface between the
two parts of an electro- pneumatic control. The most important tasks of
electrically actuated DCVs include.
• Switching supply air on or off
• Extension and retraction of cylinder drives
•
Electrically actuated directional control valves are switched with the aid of
solenoids. They can be divided into two groups:
• Spring return valves only remain in the actuated position as long as current
flows through the solenoid
• Double solenoid valves retain the last switched position even when no current
flows through the solenoid.
Cross sectional
view of a 3/2
single solenoid
valve
Various symbols for DCVs
 RELAY

• A relay is an electro magnetically actuated switch.

• It is a simple electrical device used for signal processing.
• Relays are designed to withstand heavy power surges
and harsh environment conditions.
• When a voltage is applied to the solenoid coil, an
electromagnet field results.
• This causes the armature to be attracted to the coil core.
• The armature actuates the relay contacts, either closing
or opening them, depending on the design.
• A return spring returns the armature to its initial position
when the current to the coil is interrupted.
• Relays are usually designated as K1, K2, and K3 etc.
 MECHANICAL
• Limit Switches
• Magnetic Proximity Sensors (Reed
Switches)

SENSORS ELECTRONIC
• Inductive Proximity
• Capacitive Proximity
• Optical Proximity
Mechanical Sensors
Limit Switches
 Magnetic Proximity Sensors (Reed Switches)

Reed switches Construction features of reed switch

are magnetically Reed switches are similar
actuated to relays, except a
proximity permanent magnet is
switches. used instead of a wire
coil.

Symbol of 3 wire and 2 wire reed switch

Advantages of reed switches are
• Reed switches are cheap.
• They have long service life
• They have shorter switching time
( in the order of 0.2 to 0.3 millis
seconds)
• They are compact and maintenance
frees

Disadvantages of reed switches are

• They cannot be used in environments

subjected to magnetic fields ( like
resistance welding machine)
• Closing of contacts in reed switch is
not bounce free
 Electronic sensors

• Inductive, Optical and capacitive proximity switches are electronic sensors. They
normally have three electrical contacts. One contact for supply voltage , other for
ground and third for output signal.
• In these sensors, no movable contact is switched. Instead, the output is either
electrically connected to supply voltage or to ground. There are two types of
electronic sensors with regard to the polarity of output voltage.
• Positive switching sensors: In this output voltage is zero if no part is detected in
the proximity. The approach of a work piece or machine part leads to switch over
of the output, applying the supply voltage.
• Negative switching sensors: In this the supply voltage are applied to the output if
no part is detected in the proximity. The approach of a work piece or machine
part leads to switch over of the output, switching the output voltage to 0 volts.
Inductive Proximity
• Inductive sensor use
currents induced by
magnetic field to detect the
nearby metal objects.
• The switching distance of
inductive sensors depends
on the conductivity and
permeability of the metal
part whose presence or
absence to be detected.
Advantages of Inductive proximity
sensors are
• They are self contained, rugged and
extremely reliable
• They have long service life
• They have shorter switching time
• They are compact and maintenance
frees

Disadvantages of Inductive proximity

sensors are

1. Like reed switches , they cannot be

used in environments subjected to
magnetic fields ( like resistance welding
machine)
 • Capacitive sensors are able to detect most materials
at distances up to a few centimeters.
• For capacitive sensor the proximity of any material
near the electrodes will increase the capacitance.
This will vary the magnitude of the oscillating signal
and the detector will decide when this is great
enough to determine proximity.
Capacitive
Proximity
Advantages of Capacitive proximity sensors are

• They are widely used because of their ability to react

with wide range of materials
• They are suitable for detecting non metallic objects
• They can be used to sense and monitor level in storage
containers

Disadvantages of Capacitive proximity sensors are

• They are sensitive especially in humid environment

• Without the compensator ring, the sensor would be
very sensitive to dirt, oil and other contaminants that
might stick to the sensor.
 Optical
Proximity

• Optical sensors require both a light source (emitter) and

detector.
• Emitters will produce light beams in the visible and invisible
spectrums using LEDs and laser diodes.
• The emitter and detector are positioned so that an object
will block or reflect a beam when present.
Opposed mode optical sensor
Emitter and detector in one unit
Direct and Indirect Electropneumatic Circuit
Dominant Set
(Latching/Holding
circuit with
Dominant OFF)
Dominant Reset
(Latching/Holding
circuit with
Dominant ON)
 AND
LOGIC
FUNCTION

• Cylinder is
extended using
PB1 and PB2
• Cylinder is
retracted when
either PB1 or PB2
is released
 OR LOGIC FUNCTION

Cylinder is retracted (both PB released) Cylinder is extended using PB1 or PB2

DIRECT AND INDIRECT CONYTROL OF A
DOUBLE ACTING CYLINDER
(SOLENOID DCV5/2 WITH SPRING
RETURN)
Automatic return of a
double acting cylinder
(SOLENOID DCV5/2
WITH SPRING
RETURN)
INDirect Control
of double acting
cylinder
(DOUBLE
SOLENOID DCV
5/2 )
Oscillating
motion of a
double
acting
cylinder
(Forward )
Multiple cylinder : Sequence A+ B+ A- B-

a1 b1 a0 b0

ST
A+ B+ A- B-
 PLC-PROGRAMMABLE LOGIC CONTROL
Control Systems Types

➢Programmable Logic Controllers

➢Distributed Control System
➢PC- Based Controls
Programmable Logic
Controllers
PLC
➢ Sequential logic solver
➢ PID Calculations.
➢ Advanced Subroutines
➢ BIT Operations.
➢ Data Transfer.
➢ Text Handling.
 ➢

Programmable ➢
➢
Logic
➢
Controllers
➢

➢
Programmable Logic Controllers
PLC Types

Nano (Small)

Micro (Medium)

Large

Basic criteria for PLC Types

Memory Capacity

I/O Range

Packaging and Cost per Point

 ➢
Programmable
Logic ➢
Controllers ➢
➢
 PLC Cycle

➢Sense the Input

➢Process the Logic
➢Give Output

Programmable
controller

Inputs Outputs

Machine
or
Process
Programmable Logic Controllers

Central Processing Unit

➢It is a micro-controller based circuitry. The CPU consists of following blocks :
Arithmetic Logic Unit (ALU), Program memory
Process image memory (Internal memory of CPU)
Internal timers and counters
Flags
➢CPU performs the task necessary to fulfill the PLC functions. These tasks include
Scanning, I/O bus traffic control, Program execution, Peripheral and External
device communication, special functions or data handling execution and self
diagnostics.
Programmable Logic Controllers

Input module
➢ These modules act as interface between
real-time status of process variable and
the CPU.
➢ Analog input module : Typical input to
these modules is
4-20 mA, 0-10 V
Ex : Pressure, Flow, Level Tx, RTD (Ohm),
Thermocouple (mV)
➢ Digital input module : Typical input to
these modules is 24 V DC, 115 V AC, 230
V AC
Ex. : Switches, Pushbuttons, Relays,
pump valve on off status
Programmable Logic
Controllers
Output module
➢ These modules act as link between the CPU and the output
devices in the field.
➢ Analog output module : Typical output from these modules is
4-20 mA, 0-10 V
Ex : Control Valve, Speed, Vibration
➢ Digital output module : Typical output from these modules is 24
V DC, 115 V AC, 230 V AC
Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump valve on
off control
Programmable Logic Controllers

Power Supply
➢The power supply gives the voltage required for electronics module (I/O Logic
signals, CPU, memory unit and peripheral devices) of the PLC from the line supply.
➢The power supply provides isolation necessary to protect the solid state devices
from most high voltage line spikes.
➢As I/O is expanded, some PLC may require additional power supplies in order to
maintain proper power levels.
Programmable Logic
Controllers

Bus System
➢ It is path for the transmission of the signal . Bus system is
responsible for the signal exchange between processor and
I/O modules
➢ The bus system comprise of several single line ie wires /
tracks
 PLC Signal Flow
SIGNAL INPUT SIGNAL PROCESSING SIGNAL OUTPUT
Input Module Processor Memory Output Modules

Input Data Output

Image Table Image Table
I:0/6 O:0/7
I:0/6
O:0/7
I:1/4 O:1/5

Input Devices Output Devices

Ladder Program

I:0/6 O:0/7

I:1/4 O:1/5
I:1/4 O:1/5

Programming Terminal
PLC Configuration
 • INPUT RELAYS- (contacts)These are connected to the outside world.
They physically exist and receive signals from switches, sensors, etc.
Typically they are not relays but rather they are transistors.
• INTERNAL UTILITY RELAYS- (contacts) These do not receive signals
What devices from the outside world nor do they physically exist. They are
simulated relays and are what enables a PLC to eliminate external
relays. There are also some special relays that are dedicated to
does a PLC performing only one task. Some are always on while some are always
off. Some are on only once during power-on and are typically used for
interact initializing data that was stored.
• COUNTERS- These again do not physically exist. They are simulated
with? counters and they can be programmed to count pulses. Typically
these counters can count up, down or both up and down. Since they
are simulated they are limited in their counting speed. Some
manufacturers also include high-speed counters that are hardware
based. We can think of these as physically existing. Most times these
counters can count up, down or up and down.
What devices does a PLC interact with?
Continued

TIMERS-These also do not physically exist. They come in many varieties and increments. The
most common type is an on-delay type. Others include off-delay and both retentive and non-
retentive types. Increments vary from 1ms through 1s.

OUTPUT RELAYS-(coils)These are connected to the outside world. They physically exist and
send on/off signals to solenoids, lights, etc. They can be transistors, relays, or triacs depending
upon the model chosen.

DATA STORAGE-Typically there are registers assigned to simply store data. They are usually
used as temporary storage for math or data manipulation. They can also typically be used to
store data when power is removed from the PLC. Upon power-up they will still have the same
contents as before power was removed. Very convenient and necessary!!
 PLC Architecture Evolution

• Mid - 1970s : Discrete Machine Control

Programming
Terminal

Connection is Point to Point

PLC
Programming Language :
Connection is Point to Point
- Relay ladder logic
- Flexibility in altering
Control system operation
I/O
 PLC Architecture Evolution
• Early - to - Mid 1980 : Discrete and Process Control

MS - DOS
Reasonable Computer
Running PLC
Programming Software

PLC
Programming Language :

- Ladder Program
- PID
- Data Storage
I/O
PLC Architecture Evolution

Late 1980’s to early 1990’s : Discrete and Process

Control
Windows

PC running
PLC Programming Software
Connection in networked allowing
Multiple PLC

PLC PLC

PLC became a part of the

developing enterprise resource
I/O system
 PLC Architecture Evolution

Today : Distributed I/O Modules

PLC

Distributed I/O scanner

Data Communication Bus

Distributed I/O modules

 PLC Architecture Evolution

Today : Hot Redundant System

TAPS
SPLITTERS
Remote
I/O Network
FIBER OPTIC LINK
 PLC Architecture Evolution
Today : Ethernet Technology in PLCs

Workstation Workstation Workstation Workstation

Switched Hub

Controller

Controller
Controller Controller
 PLC Architecture Evolution

Today : Wireless communication

PLC

Wireless Modem

Remote
Platform

Wireless Modem

PLC

HMI PC
Display