Introduction to Pneumatics

What is Pneumatics??
Pneumatics system use pressurized gases to transmit and control a power. As the name implies, pneumatic system typically used air as the fluid medium. Because air is safe, low cost and readily available. Pneumatic system is designed to move loads by controlling a pressurized air in distribution lines and piston with mechanical and electronic valves.
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Pneumatic system

What is the reason for considering the use of pneumatic system in stead of hydraulic system???

Cont
Liquid exhibit greater inertia than do gases. Therefore in hydraulic system the weight of the oil is a potential when accelerating and decelerating actuators and when suddenly opening and closing valves. Liquid also exhibit greater viscosity than do gases. This results in larger frictional and power losses. They require special reservoirs and no leak system design.
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Cont
Pneumatic system use air that is exhausted directly back into the surrounding environment. Generally speaking, pneumatic system are less expensive than hydraulic system. However, because of the compressibility of air, it is impossible to obtain precise, controlled actuator velocities with pneumatic system. Also precise positioning control is not obtainable.
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Pneumatics - Use
Some examples of everyday pneumatic systems are shown below. How many do you recognise?

Pneumatics - Use
Industrial application of pneumatics system are growing at rapid pace. Example stamping, drilling, hoisting, punching, clamping, assembling and material handling etc. Pneumatics are also used a lot in industry. It can be used to do lots of different jobs such as moving, holding or shaping objects.
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Pneumatics - Use
MOVE HOLD

FORM

PROCESS

What can Pneumatics do?

Operation of system valves for air, water or chemicals Operation of heavy or hot doors Unloading of hoppers in building, steel making, mining and chemical industries Ramming and tamping in concrete and asphalt laying Lifting and moving in slab molding machines Crop spraying and operation of other tractor equipment Spray painting Holding and moving in wood working and furniture making Holding in jigs and fixtures in assembly machinery and machine tools Holding for gluing, heat sealing or welding plastics Holding for brazing or welding Forming operations of bending, drawing and flattening Spot welding machines Riveting Operation of guillotine blades Bottling and filling machines Wood working machinery drives and feeds Test rigs Machine tool, work or tool feeding Component and material conveyor transfer Pneumatic robots Auto gauging Air separation and vacuum lifting of thin sheets Dental drills and so much more new applications are developed daily

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Properties of compressed air

Availability Easily stored in large volumes Simplicity in design and control Provides linear and rotary movement Installation Low system cost due to low component cost
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Properties of compressed air

Components have long working life resulting in longer system reliability Environmentally friendly Safety issues are minimized e.g.. Fire hazards; unaffected by overloads (actuators stall or slip) Pneumatic actuators in a system do not produce heat (except for friction)
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Safety Rules
Never blow compressed air at anyone, not even yourself. Never let compressed air come into contact with your skin, as this can be very dangerous. Always wear safety goggles when you are connecting and operating circuits. Check that all airlines are connected before turning on the main air supply.
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Safety Rules
Always turn off the main air supply before changing a circuit. Keep your hands away from moving parts. Avoid having airlines trailing across the floor or where someone could trip or become entangled.

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Air Production System

Air Consumption System

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Basic components of pneumatics

Compressor : it is the power source for pneumatic system. It is a machine that compresses air or another type of gas from a low pressure (usually atmospheric) to higher desired pressure level. This is actually accomplished by reducing the volume of the gas. The compressed air first stored in strong metal tank called reservoir. Air compressor generally positive displacement unit and are either of the reciprocating piston or rotary screw or 16 vane.

Compressor

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Air Compression reciprocating

Single stage

Single stage
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Air Compression rotary

Vane

screw
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Fluid conditioners
Before entering the cylinder and the valves, the compressed air has to pass through the air treatment devices, including air filter to remove dust and moisture, pressure regulator to adjust pressure, and lubricator to spray lubrication oil. Also there is mufflers, and air dryers.
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Air Receiver
A pressure Vessel (Tank) normally made of metal and installed either horizontally or vertically. This vessel provides a volume of air to be utilized by the system and reduced the loading and unloading of the compressor.

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Air filter
The function of air filter is to remove contaminants from the air before it reaches pneumatic component such as valves and actuator. Generally speaking in- line filters contain filter elements that remove contaminants in 5 to 50 micrometer range

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Air filter

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Air Dryer
Compressed air cannot hold the same amount of moisture as non compressed air. Once the air is compressed, some of the moisture condenses in the tank and is removed through a drain valve. The remaining moisture will rust internal components of the system and must be removed. One way this is done by sending the air through an air conditioned chamber which will condense more of the moisture which is present.

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Pressure regulator

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Regulating and Conditioning The compressed air to be used in a system needs to be treated because of contamination inside the system. An example of this could be the scaling of piped or worn seal material. A line filter is used to collect water and solid impurities. A Lubricator is used to vaporize oil into the air stream to lubricate moving parts in the system such as air tools.

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Pneumatics actuator
PLUNGER ROLLER TRIP PUSH BUTTON

SOLENOID

LEVER

DIAPHRAGM

ROLLER

FOOT PEDAL

PILOT AIR

SPRING
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Pneumatics actuator

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5/2 Valves
Directional control valve
Port 4 Connects to other components

Port 2 Connects to other components

Actuator will depend on valve use. In this case it is a 5/2 Pilot Pilot operated

Port 3 Exhaust Port 5 Exhaust Port 1 Main Air

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