1. Examination of the applications of pneumatic and hydraulic systems
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2. Examine the applications of pneumatic and hydraulic systems
Scenario You have recently joined a dynamic innovative engineering company as a trainee
Automation Engineer, you are required to work in the assembly of special purpose machinery and
programming robots in accordance with complex engineering drawings, producing engineering
drawings, mechanical, pneumatic & hydraulic systems, programmable logic controllers, assembly,
and functional testing / adjustment (maintenance, inspection and complying with health & safety
legislations).
Part 1: Investigate and analyse the design and function of a simple hydraulic or
pneumatic system in a production environment
A company has decided to automate its production line that involves packages being
transferred from a magazine to a chute as shown in figure 1 below, currently the process is carried
out manually; and has approached your company for a solution. Your manager has assigned this
task to you, to investigate, analyse the design and function of a simple pneumatic automation
system to be installed.
3. Fig. 1
a. Analysis of the problem (identify components) using diagrams/sketches and software
simulation package (Automation studio)
The first step is to identify the components that will be needed to create the pneumatic
automation system. These components can be identified by diagramming the system and using a
software simulation package such as Automation Studio. The following diagram shows the
components that will be needed for the pneumatic automation system:
[Diagram of the pneumatic automation system]
4. The components that are needed for the system are:
A compressor
An air tank
A solenoid valve
A pneumatic cylinder
A limit switch
A controller
b. Draw the Displacement – step diagram
5. The displacement-step diagram is a graphical representation of the pneumatic system. It
shows how the position of the pneumatic cylinder changes over time in response to the input
signals.
The following displacement-step diagram shows the operation of the pneumatic
automation system:
[Displacement-step diagram of the pneumatic automation system]
The diagram shows that the pneumatic cylinder moves to the right when the input signal
is applied. The cylinder stops moving when the input signal is removed.
c. Analyse input and output signals
The input signal to the pneumatic automation system is a switch that is located on the
magazine. When the switch is activated, it sends a signal to the controller. The controller then
sends a signal to the solenoid valve. The solenoid valve opens, allowing air to flow into the
6. pneumatic cylinder. The pneumatic cylinder then moves to the right, transferring the package to
the chute.
The output signal from the pneumatic automation system is a limit switch that is located
on the chute. When the pneumatic cylinder reaches the chute, it activates the limit switch. The
limit switch sends a signal to the controller, which then turns off the solenoid valve. This stops
the flow of air into the pneumatic cylinder, and the cylinder returns to its original position.
d. Describe the purpose and function of electrical control elements in the pneumatic
system
The electrical control elements in the pneumatic system are the switch, the controller, and
the solenoid valve. The switch is used to input a signal into the system. The controller is used to
process the signal and send a signal to the solenoid valve. The solenoid valve is used to control
the flow of air into the pneumatic cylinder.
e. Draw the power circuit (Pneumatic Circuit)
The power circuit is the circuit that supplies power to the electrical control elements in
the pneumatic system. The power circuit is shown in the following diagram:
[Power circuit for the pneumatic automation system]
7. The power circuit consists of a power supply, a fuse, and a wiring harness. The power
supply provides power to the circuit. The fuse protects the circuit from damage in the event of a
short circuit. The wiring harness connects the power supply, the fuse, and the electrical control
elements.
f. Draw the electrical circuit for direct control
The electrical circuit for direct control is the circuit that controls the pneumatic system
directly. The electrical circuit for direct control is shown in the following diagram:
[Electrical circuit for direct control of the pneumatic automation system]
8. The electrical circuit for direct control consists of a switch, a controller, and a solenoid
valve. The switch is used to input a signal into the system. The controller is used to process the
signal and send a signal to the solenoid valve. The solenoid valve is used to control the flow of
air into the pneumatic cylinder.
g. Draw the electrical circuit for indirect control using relays
The electrical circuit for indirect control using relays is the circuit that controls the
pneumatic system indirectly. The electrical circuit for indirect control using relays is shown in
the following diagram:
[Electrical circuit for indirect control using relays of the pneumatic automation system]
9. The electrical circuit for indirect control using relays consists of a power supply, a fuse, a
relay, a controller, and a solenoid valve. The power supply provides power to the circuit. The
fuse protects the circuit from damage in the event of a short circuit. The relay is used to amplify
the signal from the switch. The controller is used to process the signal and send a signal to the
solenoid valve. The solenoid valve is used to control the flow of air into the pneumatic cylinder.
h. Analyse the electro-pneumatic circuit
The electro-pneumatic circuit is the combination of the electrical circuit and the
pneumatic circuit. The electro-pneumatic circuit is shown in the following diagram:
10. [Electro-pneumatic circuit of the pneumatic automation system]
The schematic diagram of the electro-pneumatic circuit in the HSM
The electro-pneumatic circuit consists of the power circuit, the electrical circuit for direct
control, and the pneumatic circuit. The power circuit provides power to the circuit. The electrical
circuit for direct control controls the pneumatic system directly. The pneumatic circuit controls
the movement of the pneumatic
11. i. A fail-safe circuit is normally designed with the intention that the system shall fail
to the least hazardous condition and in a predetermined configuration in the event of the
air supply failing. Produce a fail-safe circuit for the Pneumatic circuit.
Sure, here is a sample fail-safe circuit for the pneumatic automation system:
[Fail-safe circuit for the pneumatic automation system]
The fail-safe circuit consists of a solenoid valve, a pneumatic cylinder, a limit switch, and
a controller. The solenoid valve is used to control the flow of air into the pneumatic cylinder. The
pneumatic cylinder is used to move the package to the chute. The limit switch is used to detect
when the package has reached the chute. The controller is used to monitor the system and ensure
that it fails to the least hazardous condition in the event of a failure.
12. In the event of a failure, the controller will open the solenoid valve, which will release the
air from the pneumatic cylinder. This will cause the pneumatic cylinder to retract, returning the
package to its original position.
Part 2: Define the purpose and function of electrical control elements in a given
hydraulic or pneumatic system
A company has automated its production line that involves metal blocks being placed in a
furnace for heat treatment over a year ago. One cylinder is used to open the furnace door, and
another pushes the metal blocks (can vary in weight) into the furnace as shown in figure 2 below.
The company has experienced issues of performance with the process (down-time due to system
failures, speed and force of actuators, doors not closing fully, hot environment, and safety
issues). Your company has been approached to review the current process of and recommend
improvements required to the circuit design (e.g., a short delay is required before Cylinder B
goes positive). You have been assigned by your department to investigate the current process
(circuit design) employed and produce a report that justifies the measures to be taken to improve
circuit design in respect of performance.
14. Report on the Improvement of a Pneumatic Circuit
A company has automated its production line that involves metal blocks being placed in a
furnace for heat treatment. One cylinder is used to open the furnace door, and another pushes the
metal blocks (can vary in weight) into the furnace. The company has experienced issues of
performance with the process (down-time due to system failures, speed and force of actuators,
doors not closing fully, hot environment, and safety issues). Your company has been approached
to review the current process and recommend improvements required to the circuit design.
Current Process
The current process is as follows:
1. An operator pushes a button to start the process.
2. Cylinder A instrokes to raise the furnace door.
15. 3. Cylinder B out-strokes and pushes the metal block into the furnace.
4. Cylinder B instrokes.
5. Cylinder A out-strokes and closes the furnace door.
6. The sequence stops.
The pneumatic circuit that carries out this operation is shown below in Figure 1.
Problems with the Current Process
The current process has a number of problems, including:
Downtime due to system failures. The pneumatic circuit is prone to
failures, which can cause downtime in the production line.
16. Speed and force of actuators. The cylinders are not powerful enough to
move the metal blocks at a consistent speed. This can lead to problems with the quality of
the heat treatment process.
Doors not closing fully. The furnace door does not always close fully,
which can lead to problems with the heat treatment process.
Hot environment. The pneumatic circuit is located in a hot environment,
which can cause problems with the components.
Safety issues. The pneumatic circuit is not safe in the event of a failure.
Recommendations
The following recommendations are made to improve the performance of the pneumatic
circuit:
Use a more reliable pneumatic circuit. The current pneumatic circuit is
prone to failures. A more reliable pneumatic circuit would reduce the amount of
downtime in the production line.
Use more powerful cylinders. The current cylinders are not powerful
enough to move the metal blocks at a consistent speed. More powerful cylinders would
improve the quality of the heat treatment process.
Add a safety mechanism to ensure that the furnace door closes fully. A
safety mechanism would prevent the furnace from being operated when the door is not
closed fully.
Move the pneumatic circuit to a cooler environment. Moving the
pneumatic circuit to a cooler environment would extend the life of the components.
17. Implement a fail-safe system. A fail-safe system would prevent the
pneumatic circuit from operating in the event of a failure.
Conclusion
The recommendations in this report will help to improve the reliability, efficiency, and
safety of the furnace automation system. By implementing these recommendations, the company
can improve its production process and reduce its risk of accidents.The following are some of the
specific benefits that can be expected from implementing the recommendations:
Increased reliability: The redesigned pneumatic system will be more
reliable and less likely to fail. This will reduce downtime and improve the efficiency of
the production process.
Improved efficiency: The upgraded pneumatic cylinders will allow the
metal blocks to be moved more quickly. This will improve the efficiency of the
production process and reduce the time it takes to heat treat the metal blocks.
Increased safety: The redesigned furnace doors will close more securely,
which will help to prevent heat from escaping and will improve safety. The relocated
pneumatic system will be in a cooler environment, which will help to extend the life of
the components and reduce the risk of leaks. The implemented safety measures will
mitigate the risks associated with the pneumatic system.
The cost of implementing the recommendations will be offset by the benefits that can be
expected, such as increased reliability, improved efficiency, and increased safety. The company is
advised to implement the recommendations as soon as possible.
18.
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