This document provides information and instructions for a practical task involving pneumatic circuits for a Mechanical Engineering diploma program. It includes the objectives, theory, problems, equipment, procedures, and assessment criteria for the task. Specifically, it covers direct and indirect control of pneumatic cylinders using various valves. The task requires students to design and implement pneumatic circuits that directly or indirectly control double-acting cylinders using buttons or pilot-operated valves to meet specified objectives. Circuits are assessed based on setup, task completion, component knowledge, and time management. Safety measures for working with compressed air are also outlined.

1. DIPLOMA IN MECHANICAL ENGINEERING (DKM4/DTP4/DEM4/DMB4)
PRACTICAL TASK 1: PNEUMATIC CIRCUIT
COURSE CODE : DJJ5123
COURSE : PNEUMATIC AND HYDRAULIC
NAME : REGISTRATION NO:
DATE : SUBMISSION DATE :
CLASS :
LECTURER :
PREPARED BY:
(PUAN ZUHAILA MOHAMMAD )
CHECKED /
APPROVED BY:
PLO 4
Practical
Task1
PLO 8 Generic Skill:
Professionalism,
Ethics and
Moral
CLO 2 CLO 3
LD 2 LD 8
A A
B B
C C
D D
E E
TOTAL MARKS
(100%)
/25
TOTAL MARKS
(100%)
/25

2. DJJ5123 PNEUMATIC AND HIDRAULIC
PRACTICAL TASK 1
Practical Skills – LD2
PLO4 apply appropriate techniques, resources, and engineering tools to well-defined mechanical engineering
activities, with an awareness of the limitations
Skills /
Aspects
Excellent Very Good Good Fair Unsatisfactory
SCORE
5 4 3 2 1
Ability to
setup
compress
air
preparation
with a safety
precaution
awareness
Follows the
standard
procedure
completely.
Followed the
standard
procedure.
Fairly followed the
standard
procedure.
Followed the
standard
procedure but
with a mistakes.
Not followed
the standard
procedure at
all.
Ability to
complete
the task
Gathered all circuit
and components
and completely
ready to start the
task.
(5/5 circuits)
Gathered all
circuit,
components,
and ready to
start the task.
(4/5 circuits)
Moderately
gathered all circuit
and components
but take a few
times to start the
task.
(3/5 circuits)
Not gathered all
needed circuit
and components
to start the task.
(2/5 circuits)
Not gathered
all needed
circuit and
components
and was
unable to
start the
task.
(1/5 circuit)
Demonstrat
e the
knowledge
of the
pneumatic
circuit
Completely know
to identify and
explain the
function of the
every pneumatic
components and
circuit flow.
Know to identify
and explain the
function of the
every pneumatic
components and
circuit flow with
guidance.
Moderately know
to identify the
function of the
every pneumatic
components and
circuit flow with
moderate
guidance.
Know the every
pneumatic
components but
circuit flow did
not know to
explain the
function.
Completely
not know to
identify and
explain the
function of
pneumatic
component
Lecturer
guidance.
Able to complete
an assembly using
Indirect Control
Using Pilot-
Operated Valve
task without
guidance.
Able to
complete an
assembly using
Indirect Control
Using Pilot-
Operated Valve
task with a little
guidance.
Moderately
complete an
assembly using
Indirect Control
Using Pilot-
Operated Valve
task with a
moderate
guidance.
Unable to
complete an
assembly Using
Indirect Control
Using Pilot-
Operated Valve
task without
major guidance.
Unable to
complete an
assembly
Using
Indirect
Control
Using Pilot-
Operated
Valve task
with
guidance.
Time
management.
(based on
successfully
task given)
Well time
management to
complete the task
successfully.
Well time
management to
complete the
task.
Moderately time
management but
not get on time
finished.
Unable to
complete the
task with
adequate time.
Unable to
complete the
task at all.
𝑆𝐶𝑂𝑅𝐸
25
𝑥 100%

4. COURSE LEARNING OUTCOMES (CLO):
Upon completion of this course, students will be able to:
CLO2. Construct accurately pneumatic, electro-pneumatic, electro-hydraulic and
hydraulic circuit according to assigned task. (P4, PLO4)
CLO3. Demonstrate understanding of engineering norm and practices in pneumatics
and Hydraulics during practical work sessions. (A3, PLO8)
SAFETY MEASURES WHEN USING PNEUMATIC CONTROL SYSTEMS

5. a. Compressed air can cause serious damage to the human body if they enter the body
through ducts like the oral cavity or ears.
b. Never spray compressed air onto anyone.
c. Under high temperature, compressed air can pass through human skin.
d. Compressed air released from the exhaust contains particles and oil droplets, which can
cause damage to eyes.
e. Even though the pressure of compressed air in pipes and reservoirs is relatively low,
when the container loses its entirety, fierce explosions may still occur.
f. Before switching on a compressed air supply unit, one should thoroughly inspect the
whole circuit to see if there are any loose parts, abnormal pressure or damaged pipes.
g. A loose pipe may shake violently due to the high pressure built up inside it. Therefore,
each time before the system pressure is increased; thorough inspection of the entire
circuit is required to prevent accidents.
h. As the force produced by pneumatic cylinders is relatively large, and the action is usually
very fast, you may suffer serious injuries if you get hit by a cylinder.
i. Switches should be installed on the compressed air supply unit to allow easy and speedy
control of air flow.
j. In case of a leakage, the compressed air supply unit should be turned off immediately.
k. The compressed air supply unit must be turned off before changes can be made to the
system.
l. Stay clear of the moving parts of the system. Never try to move the driving parts in the
mechanical operation valve with your hand.
EQUIPMENT REQUIRED
FESTO; Pneumatic Workbench
PROCEDURE

6. PROCEDURE SUMMARY
In the first part of the exercise, you will verify the status of the trainer by executing the
"trainer status verification procedure".
In the second part of the exercise, you will set up and operate a pneumatic circuit using
the Conditioning Unit, a directional control valve and a cylinder.
Trainer Status Verification Procedure
Each procedure in this manual that requires the use of the Pneumatics Trainer includes
the statement: "Verify the status or the trainer according to the procedure given in
Exercise 1-2". This status verification procedure consists of the following steps:
 Install the work surface on a work table or on a support bench, if any.
 Make sure the work surface is secured to the work table or support bench to ensure
that it will not move or fall down.
 If you use a support bench, make sure the four caster brakes are locked.
 On the Conditioning Unit, close the main shutoff valve by pushing down on the
control button.
 Pull up the regulator adjusting knob to unlock the regulator and turn it completely
counterclockwise.
 Close the four branch shutoff valves of the manifold (collar in the lower position).
Figure 3 shows the Conditioning Unit with shutoff valves.
Figure 1: Conditioning Unit with Branch Shutoff Valves.
Fundamental Pneumatic Circuit

7. 1. Locate the following components:
 Conditioning Unit;
 Directional control valve, 3-way, 2-position, pushbutton-operated;
Note: A directional control valve is a device used to open and close flow paths in a
pneumatic circuit.
 Cylinder, 2.7-cm (or 1 1/16-in) bore, 10-cm (or 4-in) stroke, single acting, and spring
return.
Note: A cylinder is an actuator that converts fluid energy into mechanical energy. Single-
acting cylinders generate force in a single direction.
Figure 2: Schematic Diagram Of A Pneumatics Circuit.
2. Mount the components on the work surface and connect the circuit shown in Figure 4
Refer to the connection diagram shown in Figure 1-21 to make your connections.
Connect the Conditioning Unit to the NC (normally non-passing) port of the directional
control valve.
Figure 3: Connection Diagram of a Pneumatic Circuit.
3. On the Conditioning Unit, open the main shutoff valve and the branch shutoff valve at
the manifold. Screw a tip (bullet) to the rod of the cylinder.

8. 4. Pull up regulator adjusting knob to unlock the regulator and turn it clockwise to set the
pressure at 200 kpa (or 30 psi0 on the regulated Pressure Gauge.
Note: Each time you set the pressure, it is recommended to close and reopen the main shutoff
valve to overcome friction. Readjust the pressure if necessary.
TASK: APPLICATIONS IN PNEUMATIC SYSTEM

9. 1.1 OBJECTIVE
i. Using Direct and Indirect Control Using Pilot-Operated Valve
ii. Students will be able to control of double-acting cylinder, and knowing various
types of speed regulation of the piston rod movement of double-acting cylinder.
1.2 THEORY
Direct control
The simplest level of control for the single or double-acting cylinder involves direct control
signals. Using this type of control, the cylinder is actuated directly via a manually or
mechanically actuated valve, without any intermediate switching of additional directional
control valves. If the port sizes of the valve are too large, the operating forces required
may be too great for direct manual operation.
Indirect Control Using Pilot-Operated Valves
To introduce the operation of pilot-operated directional control valves. To learn about
construction and classification. To show the advantages of indirect control in demo
circuits using a long line device, cylinders and a 4-way, 5-port, 2-position pilot-operated
directional control valve.
Pneumatics system performs a variety of tasks, ranging from the very simple to the
very complex. Controlling cylinders is one of the most important aspects of pneumatics.
For example, two cylinders may be required to operate at the same speed, or a cylinder
may need to extend rapidly under no load conditions.

10. 1.3PNEUMATICS PROBLEMS
A. Direct control of a double-acting cylinder with push-button.
Aim:
This exercise provides direct control of double-acting cylinders with manually
operated 5/2 directional control valves. In addition, the effect of adjustable spring
cushioning in double- acting cylinders can be observed.
Task:
 The piston rod of a double-working cylinder (Z1) should extend after actuating a
button.
 After releasing the button (S1), the piston of the cylinder should retract
automatically to its back position. Refer Figure 1.3 (a).
List of equipment’s:
Description:
i. (01) Air service unit (filter with water separator, pressure regulator and
pressure gauge) with a 3/2 directional control ball valve
ii. (02) Distributor, 6-fold
iii. (04) Double-acting cylinder with adjustable spring cushioning
iv. (08) 5/2 directional control valve with push-button Accessories
Figure 1.3 (a): Direct control of a double-acting cylinder
Circuit Problem:

11. Using the given components and layout, design a schematic circuit which will
operate one spring return cylinder from any one of three identical valves.
Design and draw schematic diagram. Approved: _______
Connect components to match schematic diagram.Approved: _______
Operate and explain circuit to instructor. Approved: _______
Conclusion:
 The double-acting cylinder can be directly controlled by a ________________________
 In the basic setting (spring position) of a directional valve, port 1 supplied with compressed
air, port 2 is always and port 4 always .

12. 1.3 PNEUMATICS PROBLEMS (continues)
B. Application
Parts are accumulating on a conveyor belt and waiting to be released and transferred to the
next phase of assembly. Technicians at multiple stations need to control the gate release
mechanism to have parts sent to their assembly station.
Objective:
To be able to design and assemble an “OR” logic circuit.
Circuit Problem:
Using the given components and layout, design a schematic circuit which will operate one
spring return cylinder from any one of three identical valves.
Design and draw schematic diagram. Approved: _______
Connect components to match schematic diagram. Approved: _______
Operate and explain circuit to instructor. Approved: _______
Layout of Components Needed:
Part
#
Component Description Qty
1 2-position, spring offset, 3-way valve 3
2 shuttle valve 2
3 push button actuator 3
4 Single acting, spring return cylinder 1
Figure: 1.3 (b)

13. C. Pressure-dependent control of a double acting cylinder
Aim:
In this exercise, the various types of speed regulation (throttling) of the piston rod
Movements of double-acting cylinders with one-way flow control valves are looked at and
the effects are observed.
Task:
- The cylinder is controlled with a manually operated button (actuator S1). After
releasing the button (S1), the piston of the cylinder should retract automatically to its
back position. Refer Figure 1.3(c)
List of equipment:
Description:
- (04) Double-acting cylinder with adjustable spring cushioning
- (08) 5/2 directional control valve with push-button Accessories
- (15) Flow control valves with non-return, adjustable
Figure 1.3(c): Speed regulation of a double-acting cylinder
Design and draw schematic diagram. Approved: _______
Connect components to match schematic diagram. Approved: _______
Operate and explain circuit to instructor. Approved: _______

14. Conclusion
Referring to Figure 1.3(c), which circuit demonstrates the following?
a. In Circuit ( ): The speed of the cylinder piston is restricted when
extending.
b. In Circuit ( ): The speed of the cylinder piston is restricted when
retracting.
c. In Circuit ( ): Both speed of the cylinder piston are restricted.

15. D. Displacement dependent control of a double-acting cylinder
Aim:
The displacement-dependent control of a double-acting cylinder by using limit
switches in demonstrated in this exercise.
Upon the completion of this task, the student will be
• Familiar with indirect actuation of a double acting cylinder by using a double pilot valve.
• Familiar with using different types of directional control valves
Task description:
Using a diverting device, parts are to be moved from one conveyor track onto the other in a
linear sequence as illustrated in Fig. 1.3(d)(i). By operating a selector valve the oscillating
piston rod of a cylinder pushes the turntable via a pawl in stepped sequence. The parts are
diverted and transported onwards in the opposite direction. By returning the selector valve
back to the normal position the drive unit is switched off.
Figure 1.3 (d)(i): Positional sketch

16. Figure 1.3 (d) (ii): Displacement dependent control of a double-acting cylinder
Conclusion:
- Design the functional diagram (stroke-time diagram) for the cylinder and
the 5/2 directional control valve.
- What are used for a displacement dependent control of a double-acting cylinder?
Design and draw schematic diagram. Approved: _______
Connect components to match schematic diagram. Approved: _______
Operate and explain circuit to instructor. Approved: _______

17. E. Pressure-dependent control of a double acting cylinder
Aim:
By using a 3/2 directional control valve with adjustable minimum pressure of response, a
pressure dependent control (and in addition displacement dependent) control of a double
acting cylinder is put into effect.
Upon the completion of this task, the student will be
• Familiar with indirect actuation of a double acting cylinder with a double pilot valve.
• Able to use and adjust the pressure sequence valve.
Taskdescription:
A plastic component is embossed using a die driven by a double-acting cylinder. The
die is to advance and emboss the plastic when a push button is operated. The return of
the die is to be effected when a preset pressure is reached. The embossing pressure is
to be adjustable.
Figure 1.3(e): Positional sketch
Task requirements:
1. Draw pneumatic circuit diagram
2. Simulate the circuit using Automation studio software.
3. Assemble the circuit practically and check its operation
List of equipment:
Description:
- (21) Pressure gauge
- (22) 3/2 directional control valve, with adjustable operating pressure
- (13) 3/2 directional control valves, with roller
- (04) Double-acting cylinder with adjustable spring cushioning
- (11) 5/2 directional control valve, impulse valve
- (15) Flow control valves with non-return, adjustable
- (06) 3/2 directional control valve, with manually operated push-button
- (13) 3/2 way roller valve for automatic return of the cylinder.

18. Figure 1.3(e) (i): Pressure dependent control of a double-acting cylinder
Conclusion:
- Mention the conditions to extend the piston of the cylinder.
- Mention the conditions to retract the piston of the cylinder.

19. Prepared by: Zuhaila Mohammad
- Design the functional diagram (stroke-time diagram) for the cylinder and the
5/2 directional control valve.
Design and draw schematic diagram. Approved: _______
Connect components to match schematic diagram. Approved: _______
Operate and explain circuit to instructor. Approved: _______
References:
1. https://www.iei.liu.se/flumes/tmms03/filarkiv/lab/1.451122/Lab2_tmms03_PneumaticControlSystems.pdf
2. https://elearning.ju.edu.jo/file.php/14990/Exp._2_Pneumatic_Control_of_a_Double-
acting_Cylinder_2017.pdf
3. Festo Didactics

20. Prepared by: Zuhaila Mohammad