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PNEUMATIC tools Industrial Training PPT P
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- 2. 2 Pneumatics 2 TPM Introduction ofpneumatic
- 3. 3 Pneumatics 3 TPM Introduction ofpneumatic
- 4. 4 Pneumatics 4 TPM Main componentof pneumatic Pneumatic compressor Dryer Pressure sensor / press gauge Pressure Regulator Pneumatic reservoir Solenoid valve Pneumatic actuator
- 5. 5 Pneumatics 5 TPM Pneumatic compressor Pneumaticcompressor is a device which converts power into compressed air.
- 6. 6 Pneumatics 6 TPM Air dryer Acompressed air dryer is used for removing water vapour from compressed air.
- 7. 7 Pneumatics 7 TPM Pressure Sensor/ press gauge ‘A pressure sensor is a device for pressure measurement of gases or liquids’.
- 8. 8 Pneumatics 8 TPM Pressure Regulator ‘Apressure regulator is a control valve that reduces the input pressure of a fluid to a desired value at its output’.
- 9. 9 Pneumatics 9 TPM ‘FRL (filter, regulator and lubricator). Is used for filter, Regulate and lubricate the air after compressor’.
- 10. 10 Pneumatics 10 TPM Solenoid valves’. •2/2 Valve push button / spring. • 3/2 Valve push button / spring • 3/2 Valve detente lever operated 2 1 3 12 10 2 10 12 1 1 2 3 12 10
- 11. 11 Pneumatics 11 TPM Solenoid valves’. •3/2 Valve differential pressure operated • 5/2 Valve push button / spring • 5/3 Valve double pressure operated spring centre 1 2 4 5 3 14 12 1 2 4 5 3 1 2 3 12 10
- 12. 12 Pneumatics 12 TPM 5/3 Solenoidvalves’. Type 1. All ports blocked Type 2. Outlets to exhaust Type 3. Supply to outlets
- 13. 13 Pneumatics 13 TPM Symbols • Non-returnvalve • Flow regulator uni-directional • Flow regulator bi-directional • Two pressure ‘AND’ • Shuttle valve ‘OR’ • Silencer • Quick exhaust valve with silencer • Pressure to electric switch adjustable
- 14. 14 Pneumatics 14 TPM Àctuator using2/2 valve • A pair of the most basic of all valve types the 2/2 can be used to control a single acting cylinder • The normally closed position of the valve is produced by the spring • The operated position is produced by the push button • One valve admits air the other valve exhausts it 2 10 12 1 1 10 12 2 OUT IN
- 15. 15 Pneumatics 15 TPM Àctuator using2/2 valve • To control the speed of the piston rod, flow restrictors are placed in the pipes close to each of the valves. • Adjustment of the restrictors will slow down the flow rate thereby giving independent outstroke and instroke speed control 10 12 10 12 OUT IN 2 1 1 2
- 16. 16 Pneumatics 16 TPM Àctuator using5/3 valve • The valve illustrated has “all ports blocked” in the mid position • Whenever the mid position is selected the pressure conditions in the cylinder will be frozen • This can be used to stop the piston at part stroke in some positioning applications • Flow regulators mounted close to the cylinder to minimise creep 2 4 1 5 3 14 12
- 17. 17 Pneumatics 17 TPM Àctuator using5/3 valve • The valve illustrated has “all ports blocked” in the mid position • Whenever the mid position is selected the pressure conditions in the cylinder will be frozen • This can be used to stop the piston at part stroke in some positioning applications • Flow regulators mounted close to the cylinder to minimise creep 2 4 1 5 3 14 12
- 18. 18 Pneumatics 18 TPM Àctuator using5/3 valve • The valve illustrated has “all ports blocked” in the mid position • Whenever the mid position is selected the pressure conditions in the cylinder will be frozen • This can be used to stop the piston at part stroke in some positioning applications • Flow regulators mounted close to the cylinder to minimise creep 2 4 1 5 3 14 12
- 19. 19 Pneumatics 19 TPM Actuator using5/3 valve • The valve illustrated has “all ports blocked” in the mid position • Whenever the mid position is selected the pressure conditions in the cylinder will be frozen • This can be used to stop the piston at part stroke in some positioning applications • Flow regulators mounted close to the cylinder to minimise creep 2 4 1 5 3 12
- 20. 20 Pneumatics 20 TPM Actuator using5/3 valve • The valve illustrated has “all ports blocked” in the mid position • Whenever the mid position is selected the pressure conditions in the cylinder will be frozen • This can be used to stop the piston at part stroke in some positioning applications • Flow regulators mounted close to the cylinder to minimise creep 2 4 1 5 3 14 12
- 21. 21 Pneumatics 21 TPM Aircylinder is an output device. It consumes compressed air and gives linear movement. It is used for moving objects, closing machine guards, punching parts, advancing slides, clamping parts etc. Air Cylinders
- 22. 22 Pneumatics 22 TPM Air Cylindersare classified as Single Acting and Double Acting Air Cylinders Single Acting Double Acting
- 23. 23 Pneumatics 23 TPM Single ActingCylinder Piston Rod Body Return Spring Airline thru’ direction control valve connected here. Exhaust port
- 24. 24 Pneumatics 24 TPM When airline is pressurized (that is connected to compressed air), force developed by air pressure is stronger than the spring and piston moves OUT, compressing the spring. Piston remains OUT as long as air line is pressurized. Single Acting Cylinder
- 25. 25 Pneumatics 25 TPM When airline is exhausted, return spring moves the piston IN. Piston will continue to remain IN as long as air line is exhausted. Single Acting Cylinder
- 26. 26 Pneumatics 26 TPM Thus aSingle acting cylinder can develop useful thrust or move objects during OUT stroke. Return spring generates IN stroke of piston. Force of return spring is enough to overcome body-piston friction only and cannot move loads.
- 27. 27 Pneumatics 27 TPM Double ActingCylinder Body Piston Rod Airline A Airline B Airlines through direction control valve are connected to these. Piston
- 28. 28 Pneumatics 28 TPM Double ActingCylinder A B When line B is pressurized and A is exhausted, piston remains IN.
- 29. 29 Pneumatics 29 TPM Double ActingCylinder A B When line A is pressurized and B is exhausted, piston moves OUT.
- 30. 30 Pneumatics 30 TPM Double ActingCylinder animated. Click on the picture to start and stop animation
- 31. 31 Pneumatics 31 TPM Cylinder ForceCalculation The thrust developed by piston rod under static conditions for OUTWARDS stroke is - Thrust F (kgs) = D2 4 X P Dia D D is piston dia in cms P is gauge pressure of air in kgs/ cm2
- 32. 32 Pneumatics 32 TPM Cylinder ForceCalculation Dia D Example : Cylinder dia 40 mm, Air Pressure – 5 bar gauge Thrust = (3.14 x 16 x 5) / 4 = 62.8 kgs Note thrust is under static conditions
- 33. 33 Pneumatics 33 TPM Cylinder ForceCalculation Dia D Piston rod dia d The thrust developed by piston rod under static conditions for INWARDS stroke is - Thrust F (kgs) = (D2 - d2) 4 X P D is piston dia in cm d is piston rod dia in mm P is gauge pressure of air in kgs/ cm2
- 34. 34 Pneumatics 34 TPM Cylinder –Mountings
- 35. 35 Pneumatics 35 TPM Direction ControlValves We have seen that a single acting cylinder needs air line alternately pressurized and exhausted in order that the cylinder operates. Direction Control Valves are Control Devices in a Pneumatic circuit that pressurize and exhaust air lines as desired.
- 36. 36 Pneumatics 36 TPM Direction ControlValves P S A This is symbol of a 3 port 2 position, Normally Closed Valve Actuation by Hand Knob Return by Spring
- 37. 37 Pneumatics 37 TPM Direction ControlValves P S A 3 ports are marked P, S and A This means on the valve, we will find 3 threaded ports.
- 38. 38 Pneumatics 38 TPM Direction ControlValves P S 2 position means the valve can remain in 2 states. One state when box 1 is operative. The other state is when box 2 is operative. A Box 1 Box 2
- 39. 39 Pneumatics 39 TPM Direction ControlValves P S When Box 1 is operative, that is valve is in position 1, ports are connected as below – P is closed. A is connected to S. A Box 1
- 40. 40 Pneumatics 40 TPM Direction ControlValves P S When Box 2 is operative, that is valve is in position 2, ports are connected as below – P is connected to A. S is closed. A Box 2
- 41. 41 Pneumatics 41 TPM Direction ControlValves P S A The ports are marked by letters as below – P is Pressure port. Connected to supply. A, B are System ports connected to devices R,S,T are Exhaust ports connected to silencers.
- 42. 42 Pneumatics 42 TPM Direction ControlValves P S A Actuation by Hand Knob, Return by Spring means – When hand knob is pressed – Box 2 is operative When hand knob is not pressed – Box 1 is operative because of the Spring. Box 1 Box 2 Spring Hand Knob
- 43. 43 Pneumatics 43 TPM Direction ControlValves P S A Thus the valve has got a tendency to remain with Box 1 operative whenever knob is not pressed. That is Normal position of valve. Since port P is closed in that position, it is called Normally Closed Valve. Box 1
- 44. 44 Pneumatics 44 TPM Direction ControlValves P S A Solenoid Actuated, Solenoid Return No defined behavior if both solenoids are ON at the same time. Care must be taken in designing electrical circuit that this does not happen. Sol 1 Sol 2
- 45. 45 Pneumatics 45 TPM Direction ControlValves Solenoid is an electromagnet. When energized it pulls a part inside the valve ( a “spool” or a “poppet”) to operate it.
- 46. 46 Pneumatics 46 TPM Such valveis called Solenoid Actuated with Internal Pilot. To restrict solenoid size and forces, in a solenoid valve, a common design is to operate the spool (or poppet) by using compressed air (available from P port) as a pilot line and solenoid valve pressurizes or exhausts the pilot line.
- 47. 47 Pneumatics 47 TPM Direction ControlValves P S A Solenoid Actuated with Internal Pilot. Spring Return. Actually a valve as per above symbol is as shown on next slide. Sol 1 Note the arrow meaning internal pilot
- 48. 48 Pneumatics 48 TPM Direction ControlValves P S A T T Pilot line Pilot Exhaust Actual construction of a Solenoid Actuated Internal Pilot Valve. Spring Return
- 49. 49 Pneumatics 49 TPM Direction ControlValves P S A Solenoid Actuated with Internal Pilot. Solenoid Return with Internal Pilot No Normal position. When both solenoids are OFF, valve remains in earlier position. Sol 1 Sol 2
- 50. 50 Pneumatics 50 TPM Pneumatic Circuit 3port 2 pos valve, (Normally Closed) is used to operate a Single Acting cylinder. When knob is not pressed, cylinder piston remains IN Supply
- 51. 51 Pneumatics 51 TPM Pneumatic Circuit Whenknob is pressed, cylinder is connected to air supply. Piston moves OUT and stays there as long as knob is pressed. Supply
- 52. 52 Pneumatics 52 TPM Pneumatic Circuit Whenthe knob is released, the piston moves IN, air from cylinder exhausts to atmosphere through port R Supply R
- 53. 53 Pneumatics 53 TPM P R S AB 5 port, 2 position valve Hand Knob Actuated, Spring Return This type of valve is used to operate a Double Acting cylinder Direction Control Valves
- 54. 54 Pneumatics 54 TPM When knobis not pressed, piston remains IN. ( If A is connected to Q and B to P, piston will remain OUT) A B P Q
- 55. 55 Pneumatics 55 TPM When knobis pressed, piston moves OUT and stays OUT Air from cylinder front end exhausts thru’ R. A B P Q R
- 56. 56 Pneumatics 56 TPM When knobis released, piston moves IN. Air from cylinder back end exhausts thru’ S A B P Q S
- 57. 57 Pneumatics 57 TPM Portsare usually BSP internal threads like 1/8”, 1/4”, 3/8”, 1/2” etc For similarly designed valves the amount of air flow through the valve usually increases with the port size. Port size alone however cannot be relied upon to give a standard value of flow as this is dependent on the design of the orifice size. Direction Control Valves – Port Size
- 58. 58 Pneumatics 58 TPM R3/8 R1/2 R1 R3/4 R1/4 R1/8 BSPThread Sizes Direction Control Valves – Port Size
- 59. 59 Pneumatics 59 TPM Direction ControlValves – Materials Manufacturers offer valves in various materials. For selection, general guidelines are – Clean, dry conditions – Aluminum Moist conditions – Brass Hazardous conditions – Stainless Steel
- 60. 60 Pneumatics 60 TPM Direction ControlValves – Construction DC valves - Spool and Poppet Type DC Valves Spool Type Poppet Type
- 61. 61 Pneumatics 61 TPM P S A XY P is connected to A S is closed X is exhausted Y is pressurized Working of a Spool Valve
- 62. 62 Pneumatics 62 TPM Specification ofa DC Valve No of ports No of Positions Actuating Mechanism –pilot, solenoid, lever etc Return Mechanism – pilot, solenoid, spring etc Normally Open or Closed – if applicable Port Size – ¼”, ½” etc Operating Pressure Body Material – Brass, Stainless Steel etc Solenoid Voltage and Current – 24V DC Any Other – flameproof coil, manual override etc Supplier’s catalogue number
- 63. 63 Pneumatics 63 TPM Flow ControlValves (Throttle Valves) Flow Control Valves are used to control speed of Cylinders during movement. Free Flow Regulated Flow Flow Control Valves allow Free flow in one direction and give Regulated Flow (which is adjustable) in the other direction.
- 64. 64 Pneumatics 64 TPM Flow ControlValves Free Flow
- 65. 65 Pneumatics 65 TPM Regulated Flow Knobfor adjustment Flow Control Valves
- 66. 66 Pneumatics 66 TPM Flow ControlValves Valve Q regulates OUT movement of the piston. Valve P regulates IN movement of the piston. P Q
- 67. 67 Pneumatics 67 TPM Pneumatic Circuits PQ Press valve P. Piston will move OUT. Release P. Press Q. Piston will move IN. Release Q. Piston will continue to remain IN.
- 68. 68 Pneumatics 68 TPM M N Pneumatic Circuits P WhenP is released, piston is IN Press P. Piston moves out. Speed regulated by M. Release P. Piston moves IN Speed is regulated by N.
- 69. 69 Pneumatics 69 TPM Manual control MN P Q Pneumatic Circuits Press and release M. Piston moves OUT. Speed regulated by Q. Piston stays OUT. Press and release N. Piston moves IN. Speed regulated by P. Piston stays IN.
- 70. 70 Pneumatics 70 TPM Manual control MN P Q Pneumatic Circuits Press and release M. Piston moves OUT. Speed regulated by Q. At end of stroke, piston presses N. Piston moves IN. Speed regulated by P. Piston stays IN. N
- 71. 71 Pneumatics 71 TPM Pneumatic Circuits– Building & Maintenance Use piping of at least same size as cylinder or valve ports. That is use 1/4” pipe for valve or cylinder with 1/4” threads. Do not use reducers and 1/8” pipes. Avoid bending load on cylinder pistons. Use clean and dry air. Protect cylinder piston rod from dirt, dust, coolant. Use standard seal kits for repairs. Protect parts from mechanical damage.
- 72. 72 Pneumatics 72 TPM Conserve CompressedAir Compressed air is very costly. One leak of dia 3 mm may equal many (say 40) lamps of 60W capacity = Leakage
- 73. 73 Pneumatics 73 TPM Strategies toconserve air – Plug all leakages. If a device can work at less than line pressure, use reduced pressure. Use single acting cylinders wherever possible. Do not use cylinders with excessive strokes. Conduct audit of compressed air.
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