Introduction to Control

System 1
 Introduction to
Control System

• The term control means methods to force parameters in

the environment to have specific values.
• In general, all the elements necessary to accomplish the
control objective are described by the term control system.
• Control system exist in nature.
• This can be as simple as
– Making the temperature in a room stay at 21˚C.
– Move large equipment with precision.
– Elevator system.
• Motor provides the power; control systems regulate the
position and speed. 2
Self Regulated System

• Liquid is flowing into a tank

at some rate Qin.
• The liquid in the tank has
some height or level h.
• so the higher the level, the
faster the liquid flows out.
• If the output flow rate is not
exactly equal to the input
flow rate, the level will either
rise or drop.
• A self regulating system
does not provide regulation,
if the input flow rate
changed, then the level
would change also, so it is
not regulated to a reference
value.
3
A Human Aided
Control System
• Artificial regulation of the level by a
human, so that it maintains the
value h.
• This can be achieved by a sensor
(sight tube, S) to measure the
level.
• The actual liquid level is called the
controlled variable.
• A valve has been added so that the
output flow rate can be changed by
the human. The output flow rate is
called the manipulated variable or
controlling variable.
• The level of height in the sight tube
is compared to the set-point value.
• If the measured value is larger, the
human opens the valve wider to
increase the output flow rate
• If the level lowers toward the set-
point. If the measured value is
smaller than the set-point, the
human closes the valve a little to
decrease the output flow rate and
allow the level to rise toward the 4
set-point.
 An Automatic
Control System
• Machines, electronics, or
computers replace the
operation of the human.
• Sensor is used to measure the
value of the level and convert it
into a proportional signal, s.
• This signal is used as input to
the controller which performs
the function of evaluating the
measurement and providing an
output signal, u.
• This control signal used to
change the valve setting via an
actuator connected to the valve
by a mechanical linkage.
• When automatic control is
applied to systems like the
example to regulate the value
of some variable to a specific
reference, it is called process
control. 5
Servo-Mechanism

• The objective is to force

some parameter to vary in
a specific manner
• In stead of regulating a
variable to a specific
reference, the
servomechanism forces the
controlled variable value to
follow variation of the
reference value
• Servo mechanisms force
the robot arm to follow a
path form point A to point
B, this done by controlling
the speed of motors
driving the arm and the
angles of the arm parts

6
 Discrete State Control Systems
• This is a type of control system concerned
with controlling a sequence of events
rather than regulation or variation of
individual variables.
• Example: the manufacture of paint.
• This sequence is described in terms of
events that are timed to be started and
stopped on a specific schedule.
• These discrete state control systems are
often implemented using specialized
computer based equipment called
programmable logic controllers (PLCs).

7
 Tank A Tank B Objective:
(Red 30%) 3 (White To produce pink color
70%) paint.

Stir

1 Valve A Valve B 2

Step1 – Turn on Valve A and

turn it off after obtained 30% of
the red paint.
Step2 – Turn on Valve B and
turn it off after obtained 70% of
the red paint.
Step3 – Turn on Stir and Heater
Mixing Tank 4
for 10 minutes.
(Pink 100%) Step4 – Turn on Valve C

3
Valve C
Heater

Tank A Tank B Tank C Tank D

8
Discrete-State Process
Control

9
 Introduction
• Many industry processes to be controlled in
sequence. The term discrete state expresses that
each event in the sequence can be described by
specifying the condition of all operating units of
the process. For example:
– Valve A is open
– Valve B is closed
– Conveyer C is on
– Limit switch S1 is closed

• A technique for designing and describing the

sequence of process events, call ladder diagram
which represents the electromechanical relays to
control the sequence in such process. The most
common control system for discrete control is
done by programmable logic controller (PLC).
10
 Definition of Discrete
State Process Control

• Figure above shows a manufacturing process and the controller for

the process. Input variable (S1, S2, S3) and output variable (C1, C2,
C3) can only be in two value. For example:
– Valves are open / closed
– Motors are on / off
– Temperature is high / low
– Limit switches are closed / open
• If there are three input variables and three output variables, then the
possible states are 64 because each variable can take on two values.
• An event in the system is defined by a particular state of the system –
as long as the input variables remain in the same state and the
output variables are left in the assigned sate. 11
Frost Free Refrigerator/Freezer

12
• The discrete-state input variables are
– Door open/closed
– Cooler temperature high/low
– Freezer temperature high/low
– Frost eliminator timer time-out/not time-out
– Power switch on/off
– Frost detector on/off
• The discrete-state output variables are
– Light on/off
– Compressor eliminator timer started/not
started
– Frost eliminator timer started/not started
– Frost eliminator heater and fan on/off
– Cooler baffle open/closed
13
• The event sequence are:
– a) If the door is opened, the light is turned on.
– b) If the cooler temperature is high and the frost
eliminator is off, the compressor is turned on and the
baffle is opened until the cooler temperature is low.
– c) If the freezer temperature is high and the frost
eliminator is off, the compressor is turned on until the
temperature is low.
– d) If the frost detector is on, the timer is started, the
compressor is turned off, and the frost eliminator
heater/fan are turned on until the timer times out.
• The events of (a) can occur in parallel with any of
the others.
• The event of (b) and (c) can occur in parallel.
• Event (d) can only be serial with (b) and (c).

14
 Continuous Control

• Consider for a moment the problem of liquid level in a tank.

Figure above shows a tank with a valve that controls flow of liquid
into the tank and some unspecified low out of the tank.
• A transducer is available to measure the level of liquid in the tank.
• The objective is to maintain the level of liquid in the tank at some
preset or setpoint value.
• If the outflow increases, the control system will increase the
opening of the input valve to compensate by increasing the input
flow rate. The level is thus regulated.
• This is a continuous variable control system because both the
level and the valve setting can vary over a range. 15
 Discrete-State Control

• Consider the revised problem shown in above; the variables, level and
valve settings, are discrete because they can take on only two values.
• The valves can only be open or closed, and the level is either above or
below the specified value.
• The objective is to fill the tank to a certain level with no outflow. The
event of sequence:
i) Close the output valve.
ii) Open the input valve and let the tank fill to the desired level,
as indicated by a simple switch.
iii) Close the input valve.
iv) Open the output valve.
16
Composite Discrete/Continuous
Control

17
• Process Hardware:
– Design the hardware such as conveyor
system, mixing tank, oven etc so that
these hardware can carry out the
designed process in-order to achieve
the objectives.
– Determination type of components such
as sensor, relay, motor etc be used in
the hardware design.
– The designer should be very familiar
with the components characteristic.

18
• Input devices: • How these two states devices
– Right box present. relate to the process?
– Left box present. • These devices give
– Feed conveyor right travel limit. information about the process
– Feed conveyor left travel limit. to the controller.
– Hopper low. • The state of the device can
– Feed conveyor center. determine the step of the
• Output devices: whole operation.
– Hopper valve solenoid. • The designer decided to use
– Feed stock conveyor motor the state of device either NO
right. or NC when design the
– Feed stock conveyor motor left. operation.
– Right box conveyor motor.
– Left box conveyor motor.
• Both NO or NC are valid, all
depend on the designer. 19
 Event Sequence Description
• A process-control engineer may not have been
involved in the development of the system
hardware construction, but they must study the
hardware carefully and understand the
characteristic of each element. Then, describe how
this hardware will be manipulated to accomplish the
objective.
• A sequence of events must he described that will
direct the system through the operations to provide
the desired end result.
• Narrative Statements Specification of the sequence
of events starts with narrative descriptions of what
events must occur to achieve the objective.
• This specification describes in narrative form what
must happen during the process operation.
• In systems that run continuously, there are
typically a startup, or initialization phase and a
running phase. 20
• The start-up phase is used to place
the feed conveyor in a known
condition. This initialization might
be accomplished by the following
specification:
I. Initialization Phase
A. All motors off, feed valve
solenoid off.
B. Test for right limit switch
1. If engaged, go to C.
2. If not, set feed motor
for right motion.
3. Start feed-conveyor
motor.
4. Test for right limit
switch.
a. If engaged, go to C.
b. If not, go to 4.
C. Set feed motor for left
motion and start.
D. Test for center switch
1. If engaged, go to E.
2. If not, go to D.
E. Open hopper-feed valve.
F. Test for left limit switch:
1. If engaged, go to G.
2. If not. go to F.
G. All motors off, hopper-feed
valve closed.
21
H. Go to running phase.
22
• Completion of this phase means that the feed
conveyor is positioned at the left limit
position and the right half of the conveyor
has been filled from the feed hopper.
II. Running
A. Start right box conveyor.
B. Test right box present switch:
1. If set, go to C.
2. If not, go to B.
C. Start feed-conveyor motor, right
motion.
D. Test center switch:
1. If engaged, g to E.
2. If not, go to D.
E. Open hopper-feed valve.
F. Test right limit switch:
1. If engaged, go to G.
2. If not, go to F.
G. Close hopper-feed valve, stop feed
conveyor.
H. Start left box conveyor.
I. Test left box present switch:
1. If set, go to J.
2. If not, go to I.
J. Start feed conveyor, left motion.
K. Test center switch:
1. If engaged, go to L.
2. If not, go to K.
L. Open hopper-teed valve.
M. Test left limit switch:
1. If engaged, go to A. 23
2. If not, go to M.
24
Flowcharts of the Event
Sequence
• It is often easier to
visualize and
construct the
sequence of events if
a flowchart is used to
pictorially present the
flow of events.
• Part of the
initialization phase of
the conveyor system
is expressed in the
flowchart format.
25
 Flowchart Symbol

Start/End Input/Output

Process Operation Decision

26
Initialization Phase

27
Running Phase

28
 Binary State Variable
Descriptions
• It used to describe the sequence of events
in terms of the sequence of discrete states
of the system.
• Each of the state, including both input and
output variables be specified.
• The input variables cause the state of the
system to change because operations
within the system cause a change of one of
the state variables.
• The output variables are change in the
system state that are caused by the control
system itself.
29
• Construct a state variable description of the process shown in
Figure bellow. The timer output (TU) is initially low when its input
(TM) is low. When TM is taken high the output stays low for five
minutes and then goes high. It resets to low when TM is taken low.
All level sensors become true when the level is reached. The
process sequence is:
1. Fill the tank to level A (LA) from valve A (VA)
2. Fill the tank to level B (LB) form valve B (VB)
3. Start the timer (TM), stir (S) and heater (H)
4. When five minute are up take stir (S) and heater (H) off
5. Open output valve (VC) until the tank is empty (LE)
6. Take the timer low (TM) and go to step 1.

30
 Input Output Description

LA LB LE TU VA VB VC TM S H

0 0 0 0 ~ 1 0 0 0 0 0 Starting state, open valve A

0 0 1 0 ~ 1 0 0 0 0 0 Reaches level LE, continue with A fill

1 0 1 0 ~ 0 1 0 0 0 0 Reaches Level A, close valve A, open valve B

1 1 1 0 ~ 0 0 0 1 1 1 Reaches Level B, close valve B, start timer, heater,

stir
1 1 1 1 ~ 0 0 1 1 0 0 Time up, stop stir and heater, open valve C to empty

1 0 1 1 ~ 0 0 1 1 0 0 Reaches level B, continue with empty

0 0 1 1 ~ 0 0 1 1 0 0 Reaches level A, continue with empty

0 0 0 1 ~ 0 0 0 0 0 0 Tank empty, turn off timer, go to first state

31
Programmable Logic
Controller (PLC) 32
 Relay Controllers and
Ladder Diagrams
• The hardware and the sequence of the event can be
combined and represent by a schematic
representation called as ladder diagram.
• It is an outgrowth of early controllers that operated
from ac lines and used relays as the primary switching
elements.
• The ladder diagram show how the hardware should be
driven so the proper sequence of events can be
accomplished.
• An industrial control system typically involves electric
motors, solenoids, heaters or coolers, and other
equipment that is operated from the ac power line.
• When a control system wants to turn on an ac motor,
this is done by a switch to energize a relay with
contact ratings that can handle the heavy load.
• Relay is the primary control element of discrete-state
control systems. 33
5-Pin Contact Relay

34
Symbol for Input Devices in Physical Ladder Diagram

35
Symbol for Output Devices in Physical Ladder Diagram

• The symbol for a motor is a

circle with a designation of M
followed by a number, as
shown in Figure a. The
control system treats this
circle as the actual motor,
although in fact, this may be
a motor start system.
• The solenoid symbol is shown
in Figure b. For example, it
may be a solenoid to open a
flow valve, or move material
off a conveyor, or a host of
other possibilities.
• The lights symbol is shown in
Figure c, is used to give
operators information about
the state of the system. The
color of the light is indicated
by a capital letter in the
circle; for example, R stands
for red, G for green, A for
amber, and B for blue. 36
Internal Relays
• A relay coil is represented by a circle
identified as CR (for control relay) and
an associated identifying number. The
contacts for that relay will be either
normally open (NO) or normally closed
(NC) and can be identified by the same
number.
• A NO contact is one that is open when
the relay coil is not energized and
becomes closed when the relay is
energized. Conversely, the NC contact
is closed when the relay coil is not
energized and opens when the relay is
energized.
• Time-delay relay as one for which the
contacts do not activate until a
specified time delay has occurred. It
designated of TR to indicate timer
relay.
• An on-delay timer relay. When the coil
is energized, the contacts are not
energized until the time delay has
lapsed.
• There is also an off-delay timer relay.
The contacts engage when the coil is
energized. When the coil is de-
energized, however, there is a time 37
delay before the contacts go to the de-
energized state.
• Figure above shows a relay used as a latch where a
green light is on when the relay is not latched and a
red light is on when the relay is latched.
• When the normally open (NO) push-button switch PB1
is depressed, control relay RL1 is energize and stays
closed.
• To de-energize or unlatch the relay, the normally
closed (NC) push button PB2 is depressed. PB2 opens
the circuit, and the relay is released. 38
PB1 PB2 R G

0 0 0 1

1 0 1 0

0 0 1 0

0 1 0 1

39
 Programmable Logic
Controller Design
• The modern solution for the problem of how to provide
discrete-state control is to use a computer-based device
called a programmable controller (PC) or programmable
logic controller (PLC).
• The move from relay logic controllers to computer-based
controllers was an obvious one because:
i) The input and output variables of discrete-state control
systems are binary in nature, just as with a computer,
ii) Many of the ""control relays" of the ladder diagram can
be replaced by software, which means less hardware
failure.
iii) It is easy to make changes in a programmed sequence
of events when it is only a change in software.
iv) Special functions, such as time-delay actions and
counters, are easy to produce in software.
v) The semiconductor industry developed solid-state
devices that can control high-power ac/dc in response
to low-level commands from a computer, including 40
SCRs and TRlACs.
FP0 PLC

41
42
Basic Element of PLC

43
 Processor
• It is used to execute a program to perform the
operations specified in a ladder diagram or a set of
Boolean equations. The processor performs arithmetic
and logic operations on input variable data and
determines the proper state of the output variables.

• It can only perform one operation at a time. That is,

like most computers, it is a serial machine. Thus, it
must sequentially sample each of the inputs, evaluate
the ladder diagram program, provide each output,
and then repeat the whole process.

• The heart of a PLC is a microprocessor such as AMD

2901 and 2903, because much of the data in PLC
operation is processed bit by bit. With the great
increases in processor speed, it is now possible to
employ a desktop personal computer with data I/O
boards running PLC software to emulate PLC
operation. 44
 Central Processing Unit (CPU)

• It containing one or more

microprocessors to handle ladder
diagram programming.
• It executes the operating system,
manages memory, monitors inputs,
evaluates the user logic, and turns
on the appropriate outputs.
• It can handle noise environment.
45
 Memory
• Read Only Memory (ROM)
– Stalled the operating system which handle the conversion of
ladder diagram to the computer language, control the data
flows and the operation of the entire PLC.
– It is nonvolatile memory.
• User Memory
– It is the array for the I/O relays, internal relays, special relays,
counter, timer.
– Each I/O, timer and counter has it own corresponding bit in
the memory.
• Random Access Memory (RAM)
– Stalled the user’s program, timer/counter values, I/O status.
– It is volatile memory.
– The memory can be sustained by the use of lithium battery.
– CMOS-RAM which is the low power consumption devices.

46
 PLC Operation
• Operation of the programmable controller can be
considered in two modes, the I/O scan mode and the
execution mode.
• I/O Scan Mode
– During the I/O scan mode, the processor updates all
outputs and inputs the state of all inputs one channel at a
time.
– The time required for this depends on the speed of the
processor.
• Execution Mode
– During this mode, the processor evaluates each rung of the
ladder diagram program that is being executed
sequentially.
– As a rung is evaluated, the last known state of each switch
and relay contact in the rung is considered, and if any TRUE
path to the output device is detected, then that output is
indicated to be energized - that is, set to ON.
– At the end of the ladder diagram, the I/O mode is entered
again, and all output devices are provided with the ON or
OFF state determined from execution of the ladder diagram
program. All inputs are sampled, and the execution mode 47
starts again.
• Scan Time
– Is time required for one complete cycle of I/O
scan and execution. This depends on how
many input and output channels are involved
and on the length of the ladder diagram
program and also depends on the clock
frequency of the processor.

– The higher the clock frequency, the greater the

speed, and the faster the scan/execution time.

– The length of time for one scan consists of

three parts i) input time, ii) execution time,
and iii) output time. Most of the scan time
comes from the execution phase.
48
 PLC Programming Devices
• Handheld Programmers
– It can be plugged into the PLC to monitor the status of inputs,
outputs, variables, counters, timers.
– It can turn the inputs and outputs on or off.
• Computer
– It can be used for offline programming and storage of
programs.
– Document the PLC program.
– Notes for technician, I/O devices.
– The document is for understanding and troubleshooting ladder
diagrams.

49
 Programming
• Although the programmable controller can
be programmed directly in ladder diagram
symbols through the programming unit,
there are some special considerations.
• These considerations include the
availability of special functions and the
relation between external I/O devices and
their programmed representations.
• The programmable controller has no "real"
relays or relay contacts. The relay used in
the ladder diagram programming is just
the software symbols.
50
 Addressing
• The programmable controller uses a similar
method of identifying devices, but if is referred to
as the device address or channel. The addresses
are used to identify both the physical and
software devices according to the following
categories:
i) Physical input devices - ON or OFF
ii) Physical output devices - energized (ON) or
de-energized (OFF)
iii) Programmed control relay coils and contacts
iv) Programmed time-delay relay coils and
contacts
v) Programmed counters and contacts
vi) Special functions

51
Type and Function of Relays

52
 PLC Wiring

PB1 PLC
Green
Input 1 Output 1
PB2 Red
Input 2 Output 2

Input 3 Output 3
+ +
Output 4 24 Vdc
24 Vdc Input 4 -
-

Com Com

53
Sensor Wiring

54
External Relay wiring

55
 Programmed Ladder Diagram
Input Devices Output Devices
PB1 (NO) – X0 L1 (Green) – Y0
PB2 (NC) – X1 L2 (Red) – Y1

Physical Ladder Diagram

56
 The Operation of the Internal Relay Contact
with Different External Input Devices
Type of Symbol Type of Symbol The The
External of the Internal of the Status of Status of
Input External Relay Internal the the
Devices Input Contact Relay Internal Internal
Devices Contact Relay Relay
Contact Contact
Before After the
the External
External Input
Input Devices
Devices be
be Pushed
Pushed
NO NO

NC

NC NO

NC 57
The Operation of the Relay with Different Connection

OFF

ON

58
The Operation of the Relay with Different Connection

ON

OFF

59
The Operation of the Relay with Different Connection

ON

OFF

60
The Operation of the Relay with Different Connection

OFF

ON

61
FPWin Pro/Trilogi/LogixPro

62
63
64
65
66
67
68
69
 Example of Discrete Control

BP BF M V

NO Start
1 0 0 1 0

NC Stop
2 1 0 0 1
3 1 1 1 0

Input Output
X0 Start Y0 M1
X1 Stop Y1 Valve
X2 BP
X3 BF 70
 Sample Solution
Start Sto p Start Sto p
CR1 CR1

CR1 CR1

BP BP BF
CR1 CR2 CR1 CR2

BF
CR1 CR3 CR1 CR2 M

CR1 CR2 M CR1 CR2 V

CR3

CR1 CR2 CR3 V

71
Sample of Solution

72
 Timer

• The timer will have an address and the preset number of

ticks to count. The timer only counts while it has a true
input. If the input becomes False and then True again, the
timer will reset to zero and start to count again.
• Figure b shows an accumulating timer, which retain a tick
count when its input goes false. When the input goes true
again, the tick count will pick up where the previous one
left off. It is necessary to have a reset input to this timer so
that, when desired, the timer can be reset back to zero. 73
74
75
 Counter

• A counter is a programmed function that counts (increments)

every time the input changes from False to True. This means
that, if in one scan the input is False and in the next scan the
input is True, the counter increments. No further counts will
occur until the input goes False again and then True.
• Counters are often drawn as a rectangle in programmed ladder
diagrams, like that shown in Figure above. There are two input
lines, one for the count input and another to reset the counter.
The counter has an address and a preset number of counts.
When the preset number of counts have been accumulated,
the counter becomes True and can activate some other part of 76
the ladder diagram.
77
 Problem 1
• Develop the physical and
programmable ladder diagram for a
motor with the following: NO start
button, NC stop button, thermal
overload limit switch opens on high
temperature, green light when
running, red light for thermal
overload

78
Solution 1: Physical Ladder Diagram

79
Solution 1: Programmed Ladder Diagram
Input Devices Output Devices

Start Button (NO) X0 Motor Y0

Stop Button (NC) X1 Green Indicator Y1

Thermal Overload X2 Red Indicator Y2

(NC)

80
 Problem 2

• When turn ON, the tank system alternately fills to level L and then
empties to level E. The level switch are activated on a rising level.
Both NO and NC connections are available for the level switches
and the ON/OFF push buttons. Prepare a physical ladder diagram
for this system.
81
Problem 2: Physical Ladder Diagram

82
 Problem 2: Programmed Ladder Diagram
Step X0 X1 X2 X3 Y0 Y1
Input Devices Output Devices
0 0 0 0 0 0
Start Button (NO) X0 Vin Valve Y0
1 1 0 0 0 1 0
Stop Button (NO) X1 Vout Valve Y1
2 1 0 1 0 1 0
L Sensor (NO) X2
3 1 0 1 1 0 1
E Sensor (NO) X3
4 1 0 1 0 0 1
5 1 0 0 0 1 0
Repeat Step 1
X 1 X X 0 0

83
 Problem 3
• Prepare a PLC ladder program for the
system of Problem 2 with the
following added requirements:
a) the system should cycle 3 times and
then quit.
b) during each cycle, there should be a
10 seconds delay after filling before
the empty phase starts. The PLC tick
time is 10 ms.

84
 Problem 3: Programmed Ladder Diagram
Input Devices Output Devices Step X0 X1 X2 X3 Y0 Y1

Start Button (NO) X0 Vin Valve Y0 0 0 0 0 0 0

Stop Button (NO) X1 Vout Valve Y1 1 1 0 0 0 1 0

L Sensor (NO) X2 2 1 0 1 0 1 0

E Sensor (NO) X3 3 1 0 1 1 0 0

Delay 1.5 minutes

4 1 0 1 1 0 1

5 1 0 1 0 0 1

6 1 0 0 0 1 0

Repeat for 100 times for Step 1

X 1 X X 0 0

85
 Pneumatic Cylinder

• Single Acting cylinder only extends by pressure from a pump and then retracts by
the weight of the load or by an inbuilt spring. A Double Acting cylinder uses
hydraulic power to both extend and retract.
• A single acting hydraulic cylinder is simpler, so there is less to maintain. With only
one line the action of the cylinder is determined entirely by the pressure on that
one line. They often have a spring or something similar to push or retract the
piston rod, but they might rely on the force on end to push it back. Simplicity is
always good for equipment that needs to be rugged and reliable.
• A double acting cylinder alternates cycles of pressurized fluid to both sides of the
piston and creates extend and retract forces to move the piston rod, permitting
more control over the movement. Using a control system made up of a 2-, 3-, 4-
way position valve would be required to achieve the desired movement for your 86
application.
 Valves
• Valve are defined as devices to control or regulate the
commencement, termination and direction and also the
pressure or rate of flow of a fluid/gas under pressure which is
delivered by a compressor or vacuum pump or is stored in a
vessel.
• Values of one sort or another, perform three main function in
pneumatic installation
– They control the supply of air to power units, example cylinders
– They provide signal which govern the sequence of operation
– They act as interlock and safety devices

87
Types of Direction Control Valves

88
Control Valves Operation
Valve Operation

3/2 Directional Control

Valve (Normally Closed)

2(A)

Initial Stage
1(P) 3(R)

2(A)

Energized Stage
1(P) 3(R)

89
 3/2-Way Pneumatic Solenoid Valves

• The 3/2-way pneumatic valve has three connection ports and two
states. The three ports are:
– inlet (P, 1),
– outlet (A, 2)
– exhaust (R, 3)

• The two states of the valve are open and closed. When the valve is
open, air flows from the inlet (P, 1) to the outlet (A, 2). When the
valve is closed, air flows from the outlet (A, 2) to the exhaust (R, 3).
• A valve that is closed in non-actuated state is normally closed (N.C.),
the opposite is called normally open (N.O.). 90
• Most valves are mono-stable and return to their default
position when not actuated, this is achieved with a spring
mechanism. Bi-stable 3/2-way valves retain their position
during power loss, and require a separate action to switch the
valve state. Therefore, they cannot be designated as Normally
Closed or Normally Open. Bi-stable pneumatic solenoid valves
typically have a coil at each position and are pulse operated.
Summarized, the different functions of the 3/2-way valve are:
– 3/2-way mono-stable NC
– 3/2-way mono-stable NO
– 3/2-way bi-stable

91
 3/2-Way Pneumatic Solenoid Valves Application

Controlling a single acting cylinder

• Operating a single acting cylinder is a typical application of 3/2-way
valves. A single acting cylinder has one pneumatic port to fill and
empty the air chamber. The cylinder moves in one direction by filling
the air chamber, and returns by spring force. The 3/2-way valve
either fills the air chamber or vents the chamber to the atmosphere.
A basic pneumatic circuit for a single acting cylinder can found on
the picture below.

92
 3/2-Way Pneumatic Solenoid Valves Application

Controlling a double acting cylinder

• A double acting cylinder has two air chambers. The cylinder is moved by
filling one air chamber while venting the other. Each chamber has its own
connection port, so in most cases a 5/2-way valve is used to operate a
double acting cylinder.
• However, it can also be done with two 3/2-way valves that each connect to a
port of the cylinder. One valve drives the piston rod to the extended position
(a1), the other valve drives the piston back to its initial position (a0).
• One advantage of these circuits is that two different pressures can be applied
to the cylinder ports, without installing a pressure regulator between the
valve and the cylinder. Another advantage is that the two air chambers can
be vented simultaneously, resulting in free movement of the piston rod. with
a 5/2-way valve this is not possible.
• To drive the piston with two NC valves from position a0 to a1, one valve needs
to be energized (switched on, 1) while the other needs to be de-energized
(switched off, 0). The valve that is switched off lets compressed air exhaust
at the port (R,3). Therefore, the piston moves to the required direction.
• At least one of the two valves should be in the "exhaust" position, to not
pressurize both cylinder ports at the same time. When both cylinder ports are
pressurized, the piston movement depends on the previous state of the
piston, the amount of pressure, the cylinder type, etc.

93
94
95
 4/2-Way Pneumatic Solenoid Valves

• The 4/2-way pneumatic valve has four connection ports and two
states. The difference between the two valve types is the number of
exhaust ports:
– A 5/2-way pneumatic valve has two independent exhaust ports
– A 4/2-way valve has only one common exhaust port
• This means that both port (A,2) and (B,4) connect to exhaust port
(R,3). The additional exhaust port of the 5/2-way valve offers extra
control possibilities. For example, the speed in both directions of a
double acting pneumatic actuator can be adjusted by controlling the
flow rate through each exhaust port individually with throttle valves.
96
 5/2-Way Pneumatic Solenoid Valves

• The 5/2-way pneumatic valve has five connection ports and two
states. It has one pressure port (P,1), two ports (A,2) and (B,4) that
connect to the device that needs to be controlled, and two exhaust
ports (EA,3) and (EB,5). The two states of the valve are:
• Pressure port (P,1) connects to port (A,2), while port
(B,4) vents through exhaust port (EB,5)
• Pressure port (P,1) connects to port (B,4), while port
(A,2) vents through port (EA,3).

97
 5/2-Way Pneumatic Solenoid Valves Application

• 5/2-way valves are used to actuate double acting pneumatic

actuators, such as cylinders, rodless cylinders, grippers and rotary
actuators. Double acting actuators require compressed air to move in
both directions. To decide whether a mono-stable or bi-stable 5/2-
way valve should be applied, it is necessary to know more about the
system’s design and requirements. 98