Chapter 1

Module 1: Introduction

Table of Contents
Pneumatics Overview ........................................................................................................... 1-2
 Definition ........................................................................................................................... 1-3
Features of Pneumatics system............................................................................................. 1-7
 Advantages of linear drives used in pneumatic application .............................................. 1-7
 Characteristics of Pneumatic cylinder .............................................................................. 1-8
 Types of motion with Pneumatic components ................................................................. 1-6
Industrial Application of Pneumatic Systems ........................................................................ 1-9
Advantages and Disadvantages in use of compressed air in fluid control systems .................. 1-9
Structure and Signal flow of pneumatic system ..................................................................... 1-9

Reference ............................................................................................................................... 1-

Table of Figure
Figure 1: Application of pneumatics i _________________________________________ Error! Bookmark not defined.
Figure 2: Application of pneumatics ii ________________________________________ Error! Bookmark not defined.
Figure 3: Advantages of use of air ___________________________________________ Error! Bookmark not defined.
Figure 4: Disadvantages of use of air _________________________________________ Error! Bookmark not defined.
Figure 5: Signal flow ______________________________________________________ Error! Bookmark not defined.
Figure 6: Signal flow with symbols ___________________________________________ Error! Bookmark not defined.

What you will cover

Module 1: Pneumatics: Introduction
Features and structure of Pneumatics system
Industrial Application of Pneumatic Systems
Advantages and Disadvantages in use of compressed air in fluid control systems

Learning Outcome
At the end of this module participants will be able to:
Understand the Features and structure of Pneumatics system
Understand the Industrial application of pneumatic systems
Understand the advantages and disadvantages in use of compressed air in fluid control systems

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 Module 1: Introduction

Pneumatics Overview

• PNEUMATICS is from the Greek word “Pneuma” which means breath or wind
• As a science: the study of air (gas) movement and phenomena
• As a technology: It is the use of [compressed] air to do work (industrial application)

Definition: Thus, Pneumatics Automation Systems, is the use of compressed air to control
machines or manufacturing processes through various pneumatic valves and actuators.

Pneumatics in review
Pneumatics has long since played an important role as a technology in the performance of
mechanical work. It is also used in the development of automation solutions. In the majority of
applications compressed air is used for one or more of the following functions:

 To determine the status of processors (sensors)

 Information processing (processors)
 Switching of actuators by means of final control elements
 Carrying out work (actuators)

To be able to control machinery and installations necessitates the construction of a generally

complex logic interconnection of statuses and switching conditions. This occurs as a result of the
interaction of sensors, processors, control elements and actuators in pneumatic or partly
pneumatic systems.

The technological progress made in material, design and production processes has further
improved the quality and diversity of pneumatic components and thereby contributed to their
widely spread use in automation.
The pneumatic cylinder has a significant role as a linear dive unit, due

 to its relatively low cost.

 ease of installation,
 simple and robust construction and
 ready availability in various sizes and stroke lengths.

The pneumatic cylinder has the following general characteristics:

 Diameters 2.5 to 320 mm
 Stroke lengths 1 to 2000 mm
 Available forces 2 to 45000 N at 6 bar
 Piston speed 0.1 to 1.5 m/s

Pneumatic components can perform the following

types of motion:
 Linear
 Swivel
 Rotary

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 Module 1: Introduction

Some industrial applications employing pneumatics are listed below:

General methods of material handling:

-Clamping
-Shifting
-Positioning
- Orienting
- Branching of material flow

General applications:
- Packaging
- Filling
- Metering
-Locking
-Driving of axes
-Door or chute control
-Transfer of materials
-Turning and inverting of parts
-Sorting of parts
-Stacking of components
-Stamping and embossing of components

Pneumatic is used for carrying out machining and work operation such as:
Drilling
Turning
Milling
Sawing
Finishing
Forming
Quality control

Advantages and Disadvantages of Pneumatic automation system

Advantages

Availability Air is available practically everywhere in unlimited quantities

Transport Air can be easily transported in pipelines, even over large distances
Storage Compressed air can be stored in a reservoir and removed as required.
In addition, the reservoir can be transportable
Temperature Compressed air is relatively insensitive to temperature fluctuations.
This ensures reliable operation, even under extreme conditions.
Explosion proof Compressed air offers no risk of explosion or fire
Cleanliness Unlubricated exhaust air is clean. Any unlubricated air which escapes
through leaking pipes or components does not cause contamination
Components The operating components are of simple construction and therefore
relatively inexpensive
Speed Compressed air is a very fast working medium. This enables high working
speeds to be attained.

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Disadvantages

Preparation Compressed air requires good preparation. Dirt and condensate

should not be present
Compression It is not always possible to achieve uniform and constant piston
speeds with compressed air.
Force Compressed air is economical only up to a certain force requirement.
requirement Under the normal working pressure of 600 to 700 kPa (6 to 7 bar) and
dependent on the travel and speed, the output limit is between
40 000 and 50 000 Newton
Noise level The exhaust air is loud. This problem has now. however been largely
solved due to the development of sound absorption material and
silencers

A comparison with other forms of energy is an essential part of the selection process when
considering pneumatics as a control or working medium. This evaluation embraces the total
system from the input signal (sensors) through the control part (processor) to the control
elements and actuators.

All factors must be considered such as:

 Preferred control methods

 Available resources
 Available expertise
 Systems currently installed which are to be integrated with the new project

Structure and signal flow of pneumatic systems

Pneumatic systems consist of an interconnection of different groups of elements

This group of elements forms a control path for signal flow, starting from the signal section
(input) through to the actuating section (output).

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Control elements control the actuating elements in accordance with the signals received from
the processing elements.

The primary levels in a pneumatic system are:

 Energy supply
 Input elements (sensors)
 Processing elements (processors)
 Control elements
 Power components (actuators)

The element in the systems are represented by symbols which indicate the function of the
element

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