VALVE

A valve is a mechanical device used to control the flow and

pressure within a system or process. It can start, stop, or regulate
the flow of a fluid (liquid, gas, or slurry) through pipes or
passageways.

Types of Valves and Their Applications:

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1. Gate Valve

Definition:
A gate valve is a linear motion valve used to start or stop fluid flow.
It works by lifting a gate out of the path of the fluid.

Construction & Working:

It has a flat or wedge-shaped gate which moves up and down.

When the gate is lifted, the valve opens and allows full flow.

When lowered, it shuts off the flow.

Advantages:

Minimal pressure loss

Good for on/off control

Disadvantages:

Not suitable for flow regulation

Slow operation

Applications:

Water supply systems

Oil and gas pipelines

Power plants

Marine systems
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2. Globe Valve

Definition:
A globe valve is a linear motion valve used for regulating flow. It
has a globe-shaped body and a disc that moves up and down to
control flow.

Construction & Working:

Fluid passes through a restricted opening.

Flow is adjusted by the vertical movement of the disc.

Advantages:

Excellent throttling capability

Good shut-off

Disadvantages:

Higher pressure drop

More complex design

Applications:

Fuel oil systems

Cooling water systems

Steam lines

Chemical industries

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3. Ball Valve

Definition:
A ball valve is a quarter-turn valve that uses a hollow, perforated,
and pivoting ball to control flow.

Construction & Working:

Turning the ball 90° opens or closes the valve.

Provides tight sealing even after long use.

Advantages:

Quick operation

Durable and reliable

Low maintenance

Disadvantages:

Not suitable for throttling

Prone to wear if used frequently for partial opening

Applications:

Gas pipelines

Water distribution

HVAC systems

Pharmaceuticals
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4. Butterfly Valve

Definition:
A butterfly valve is a quarter-turn rotary valve used to regulate
flow, using a disk that rotates to open or close the passage.

Construction & Working:

The disc is mounted on a rotating shaft.

A simple 90° turn opens or closes the valve.

Advantages:

Lightweight and compact

Quick operation

Cost-effective

Disadvantages:

Not suitable for high-pressure systems

Can cause pressure drops

Applications:

Water treatment

Fire protection systems

Food processing

Slurry and vacuum services

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5. Check Valve

Definition:
A check valve allows flow in one direction and prevents backflow,
functioning automatically.

Construction & Working:

Common types include swing check, lift check, and ball check.
The valve closes when flow reverses due to gravity or pressure.

Advantages:

Prevents backflow

Automatic operation

Low maintenance

Disadvantages:

No manual control

Can cause water hammer in pipelines

Applications:

Pump discharge lines

Sewage and wastewater systems

Compressed air systems

Marine and irrigation

Electro-Pneumatic System

Introduction:

An electro-pneumatic system combines electrical and pneumatic

technologies to control mechanical movements using compressed
air and electrical signals. It enhances the automation and efficiency
of industrial processes.

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Definition:

An Electro-Pneumatic System is a system where electrical control

devices (such as sensors, switches, relays, PLCs) are used to operate
pneumatic actuators like cylinders and valves through solenoid-
operated directional control valves.

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Main Components of Electro-Pneumatic System:

1. Compressor:
Generates and supplies compressed air to the system.

2. Air Treatment Units:

Filters, lubricates, and regulates the air before use (FRL unit: Filter-
Regulator-Lubricator).

3. Pneumatic Actuators:

Convert pneumatic energy into mechanical motion.

Examples: Single/Double-acting Cylinders.

4. Directional Control Valves (DCVs):

Control the path of airflow.

Operated by solenoids (electromagnetic coils).

5. Electric Sensors and Switches:

Detect positions and conditions (e.g., limit switches, proximity
sensors).

6. Solenoids:

Convert electrical signals into mechanical movement to control

valves.

7. Relay/Timer/PLC:

Used for sequencing, timing, and logical control of operations.

8. Connecting Tubes and Fittings:

Carry air between components.

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Working Principle:

1. Electrical signal is sent by a sensor or controller.

2. The signal energizes the solenoid coil in the valve.

3. The energized valve shifts and directs compressed air to the

actuator.

4. The actuator performs the required mechanical task (like

pushing a piston).

5. Once the task is complete, sensors provide feedback for further

control or next operation.

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Types of Electro-Pneumatic Systems:

1. Single-Acting System:
Air moves the piston in one direction; spring returns it.

2. Double-Acting System:

Air controls both extension and retraction of the piston.

3. Sequential System:

Multiple operations performed in a specific order using sensors

and timers.

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Advantages:

Faster and more precise operation

Easy automation and control

Suitable for repetitive tasks

Reduces human error and fatigue

Cost-effective for short to medium-range operations

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Disadvantages:

Needs compressed air supply

Not suitable for high-force applications

Can be noisy

Air leaks may affect performance

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Applications:

Automatic assembly lines

Material handling equipment

Packaging machines

Conveyor systems

Robotics and pick-and-place units

Automotive industry

Here's a 16-mark answer on Proximity Sensors, including Inductive

and Capacitive Proximity Sensors:

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Proximity Sensors

Introduction:

A proximity sensor is a non-contact sensor that detects the

presence, absence, or distance of an object within a specified range.
It works based on physical properties such as metallic nature,
dielectric constant, or magnetic field.

Proximity sensors are used in automation, robotics, CNC machines,

conveyors, and safety applications.
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Types of Proximity Sensors:

The two main types commonly used in industrial systems are:

Inductive Proximity Sensor

Capacitive Proximity Sensor

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1. Inductive Proximity Sensor

Definition:

An inductive proximity sensor is used to detect metallic objects

without physical contact. It operates on the principle of
electromagnetic induction.

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Construction:
Oscillator: Produces a high-frequency electromagnetic field.

Coil: Generates magnetic field at the sensing face.

Detector Circuit: Monitors changes in the field.

Output Circuit: Provides switching signal to external devices.

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Working Principle:

When a metallic object enters the magnetic field, eddy currents are
induced in it.

These eddy currents change the amplitude of oscillations.

The sensor detects this change and activates the output signal.

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Characteristics:
Only detects metallic objects.

High accuracy and repeatability.

Short sensing range (typically 1–10 mm).

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Applications:

Metal detection on conveyor belts

Position sensing in CNC machines

Counting metal parts in production lines

Safety interlocks in machines

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2. Capacitive Proximity Sensor

Definition:
A capacitive proximity sensor is used to detect both metallic and
non-metallic objects, including solids and liquids, based on the
change in capacitance.

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Construction:

Sensor Electrode: Forms one plate of the capacitor.

Target Object: Acts as the second plate or affects the dielectric.

Oscillator and Detection Circuit: Measure change in capacitance.

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Working Principle:

When an object enters the sensing field, it alters the capacitance

between the plates.

This change is sensed by the circuit, which triggers the output.

The magnitude depends on the dielectric constant of the object.

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Characteristics:

Detects metal, plastic, wood, paper, liquid, etc.

Sensitive to environmental factors (humidity, dust).

Adjustable sensing range (typically up to 25 mm).

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Applications:

Liquid level detection in tanks

Detecting plastic or glass containers

Presence detection of paper in printers

Food processing and packaging lines

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Comparison Table:
Limit Switch

Introduction:

A limit switch is an electromechanical device used to detect the

presence or absence of an object, or to monitor and indicate
whether the movement limits of a machine component have been
exceeded. It is widely used in industrial automation and control
systems.

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Definition:

A limit switch is a mechanical device that consists of an actuator

linked to a set of contacts. When an object comes in contact with
the actuator, the switch operates to open or close an electrical
circuit.

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Construction:

Actuator/Operating Head: Moves when contacted by the object.

Switch Body: Contains the contact mechanism.

Electrical Terminals: Used to connect the switch to the control

circuit.

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Working Principle:

When a moving object (like a machine part) comes into physical

contact with the actuator, it pushes it.

This causes the internal contacts to change their state (NO becomes
NC or vice versa).

The electrical signal from the switch is used to stop, start, or

reverse a process.

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Types of Limit Switches:

1. Lever Type Limit Switch

Operation: Activated by a lever arm pushed by the object.

Application: Used in elevators, CNC machines, and conveyors.

2. Plunger Type Limit Switch

Operation: Activated by the direct push of a button or plunger.

Application: Accurate end-position sensing in machine tools.

3. Roller Lever Type Limit Switch

Operation: Has a lever with a roller for smooth operation.

Application: Detected where sliding motion is present.

4. Rotary Limit Switch

Operation: Uses rotating shafts and gears to trigger contacts.

Application: Hoisting equipment, cranes, and elevators.

5. Whisker or Spring Rod Type

Operation: Has a thin flexible rod for sensitive touch detection.

Application: Used in light-duty applications or sensitive detection.

6. Proximity Limit Switch

Operation: Non-contact type using sensors (e.g., inductive,

capacitive).

Application: Advanced automation systems for speed and

reliability.

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Symbols of Limit Switch (as per standards):

NO (Normally Open) Contact

NC (Normally Closed) Contact

Mechanical Actuator Symbol

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Applications of Limit Switches:

Conveyor systems to detect object position

Door interlock systems

Machine tool limit position detection

Elevator and hoist position control

Safety shut-off systems

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Advantages:

Simple design
High reliability

Accurate position sensing

Cost-effective

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Disadvantages:

Requires physical contact (wear and tear)

Can be affected by dust and oil

Not suitable for very high-speed applications