basic pneumatics.pdf

AASTU DEPARTEMENT OF MECHANICAL ENGINEERING
MECHATRONICS LAB BASIC PNEUMATIC CIRCUIT SOLUTION MANUAL
1
Exercise 1: Pressing of cheese wheels
Solutions
Exercise 1: Pressing of cheese wheels
Name: Date:
Completing the pneumatic circuit diagram Sheet 1 of 1
Initial position:
In the normal position, the direction of flow in the valve is closed. The piston rod of cylinder A1
is retracted.
Steps 1-2
If the pushbutton of the 3/2-way valve 1S1 is pressed, compressed air flows into the Piston
chamber and the cylinder 1A1 advances.
Steps 2-3
If the pushbutton is released, the valve exhausts and the cylinder returns into its initial position
as a result of the reset spring action.
Compile the equipment list by entering the required equipment in the table below.
1 Cylinder, single-acting
1 3/2-way valve with pushbutton, normally closed
1 Manifold
1 Start-up valve with filter control valve
1 Compressed air supply

2
Exercise 2: opening of an animal feed silo
Solution
Exercise 2: Opening of an animal feed silo
Name: Date:
Completing the pneumatic circuit diagram Sheet 1
Initial position
The 3/2-way valve is open in the direction of flow and the piston chamber is pressurized. The
piston rod of the cylinder is extended.
Steps 1-2
If pushbutton 1S1 is pressed, the piston exhausts via the 3/2-way valve and the cylinder
retracts.
Steps 2-3
If the pushbutton is released again, the spring pushes the 3/2-way valve into the normal
position, the piston is pressurized and the cylinder advances again.
1 Manifold

3
Exercise 3: Testing of key blanks
Solutions
Exercise 3: Testing of key blanks
Name: Date:
Initial position
The direction of flow is closed in the valve. The cylinder piston rod is retracted.
Steps 1-2
If the selector switch 1S1 is actuated, compressed air flows into the piston chamber and the
cylinder advances.
Steps 2-3
If the selector switch is reset, the valve exhausts and the cylinder returns into the initial position
as a result of the effect of the reset spring.
Amend the equipment list by entering the required equipment in the table below.
1 yylinder, double-acting
1 5/2-way valve with selector switch
1 Manifold
1 1Compressed air supply

4
Exercise 4: Sorting of packages
Solutions
Exercise 4: Sorting of packages
Name: Date:
Initial position
The righthand supply port of the cylinder is pressurised and the lefthand port exhausted. The
piston is retained in the retracted end position.
Steps 1-2
If the selector switch is actuated the valve switches and the lefthand port of the cylinder is
pressurised and the righthand port exhausted. The cylinder moves into the forward end
position. The cylinder remains in this position even if the selector switch is not held.
Steps 2-3
If the selector switch is reset the cylinder returns into the initial position.
1 yylinder, double-acting
1 Manifold
1 1Compressed air supply

5
Exercise 5: Stopping crates of drinks
Solutions
Name: Date:
Initial position
Both the signaling element and control element are in the position created by the reset spring.
Steps 1-2
If the selector switch of the 3/2-way valve 1S1 is actuated, this switches through and the
pneumatic control port 14 of the 5/2-way valve 1V1 is pressurized, thereby switching the 5/2-
way valve.
The left-hand port (piston side) of the double-acting cylinder is pressurized, the right hand port
(piston rod side) is exhausted and the cylinder advances.
Steps 2-3
If the selector switch is reset, the compressed air in the 3/2-way valve is blocked, the 5/2-way
valve loses pressure at the control port 14 and switches. This causes the piston side of the
cylinder to exhaust and the piston rod side to be pressurized. The cylinder moves into the
retracted end position.
1 Cylinder, double-acting
1 5/2-way valve, pneumatic, with reset spring
1 3/2-way valve, selector switch, normally closed
1 Manifold

6
Exercise 6: Opening and closing of a pipe
Solutions
Name: Date:
Initial position
In the initial position the piston assumes the retracted end position. The piston chamber is
exhausted via the 5/2-way valve using selector switch 1S1.
Steps 1-2
Switching of the 5/2-way valve causes the cylinder piston chamber to be pressurized via the
one-way flow control valve. The double-acting cylinder moves into the forward end position.
The required advancing time is set via the one-way for flow control valve. Use a stop watch to
do so. The required setting can be fixed via the lock nut.
Steps 2-3
When the selector switch is reset the cylinder piston chamber is pressurized via the one-way
flow control valve and the 5/2-way valve. The cylinder moves into the retracted end position.
2 One-way flow control valve
2 Pressure gauge
1 Manifold
1 Start-up valve with filter control va

7
Exercise 7: Shutting off using a quick shut-off function
Solutions
Exercise 7: Shutting off using a quick shut-off function
Name: Date:
Initial position
In the initial position, the piston assumes the retracted end position. The piston chamber is
exhausted via the 5/2-way valve 1S1.
Steps 1-2
Switching of the 5/2-way valve causes the cylinder piston chamber to be pressurized via the
one-way flow control valve. The cylinder advances into the forward end position.
Steps 2-3
Resetting of the selector switch causes the cylinder piston chamber to be pressurized via the
one-way flow control valve and the 5/2-way valve. The cylinder moves into the retracted end
position.
The required retracting time is set via the one-way flow control valve. Use a stop watch to do o.
The required setting can be fixed using the lock nut.
2 Pressure gauge
1 Manifold
1 Start-up valve with filter control va

8
Exercise 8: Actuating a shut-off device
Solutions
Exercise 8: Actuating a shut-off device
Name: Date:
Initial position
In the initial position the piston assumes the retracted end position. The piston chamber is
exhausted via the 5/2-way double-pilot valve and the piston rod chamber is pressurized.
Steps 1-2
Actuation of the 3/2-way valve 1S1 causes the 5/2-way double pilot valve to reverse, the
cylinder piston chamber is pressurized via the one-way flow control valve. The double-acting
cylinder advances into the forward end position. The piston rod chamber is exhausted via the
quick exhaust valve.
Steps 2-3
Actuation of the 3/2-way valve 1S2 causes the 5/2-way double pilot valve to be reversed. The
piston rod chamber of the cylinder is pressurized via the quick exhaust valve. The cylinder
piston chamber is exhausted via the one-way flow control valve and the 5/2-way double pilot
valve. The cylinder moves into the retracted end position.
Retracting time .The required retracting time is set via the one-way flow control valve. Use a
stop watch to do so. The required flow control setting can be fixed using the lock nut.
1 Quick exhaust valve
1 Pressure gauge
1 5/2-way double pilot valve
1 Manifold

9
Exercise 9: Brushing of cheese wheels
Solutions
Exercise 9: Brushing of cheese wheels
Name: Date:
Initial position
Pressure is available. The piston chamber of the double-acting cylinder is exhausted, the piston
rod chamber is pressurized and the cylinder is in the retracted end position.
Steps 1-2
If the pushbutton of valve 1S1 is actuated, the cylinder 1A1 advances. The cylinder remains in
the forward end position as a result of the self-latching loop.
Steps 2-3
Once the pushbutton of the normally open valve 1S2 is actuated the cylinder retracts again.
The self-latching loop is switched off. The 5/2-way valve switches to normal position and the
piston rod chamber is pressurized. The cylinder moves into the retracted end position.
1 5/2-way valve, pneumatic, with spring return
1 3/2-way valve with pushbutton, normally open
1 3/2-way valve, pneumatic, normally closed
1 Shuttle valve (OR)
1 Manifold
1 Compessed air supply

10
Exercise 10: Clamping of a workpiece
Solutions
Exercise 10: Clamping of a workpiece
Name: Date:
Initial position
Pressure is available. The piston chamber of the double-acting cylinder is exhausted and the
piston rod chamber is pressurized. The 3/2-way roller lever valve 1B1 is actuated. The cylinder
is in the retracted end position.
Steps 1-2
If the pushbutton of the 3/2-way valve 1S1 is actuated, compressed air is applied at both inputs
of the dual pressure valve 1V1 and compressed air is now available at the output of the dual
pressure valve. The 5/2-way double pilot valve 1V2 is reversed via the signal applied at the
control port 14.This causes the cylinder to reverse and the piston to advance. The 3/2-way
roller lever valve switches to normal position and the output signal at the dual pressure valve is
switched off. The cylinder remains in the forward end position due to the self-latching circuit.
Steps 2-3
Actuation of the pushbutton on the 3/2-way valve 1S2 causes the 5/2-way double pilot valve
1V2 to reverse again (signal at pilot port 12).The piston rod chamber of the cylinder is
pressurized and the cylinder moves into the retracted end position. The 3/2-way roller lever
valve 1B1 is actuated again.
1 Cylinder, double-acting 1,3/2-way valve with pushbutton, normally closed
2 One-way flow control valve 1,Manifold
2 Pressure gauge 1,Start-up valve with filter control valve
1 5/2-way valve, pneumatic 1,Compressed air supply
1 Dual pressure valve (AND) 2,3/2-way valve with pushbutton, NC
1 3/2-way roller lever valve, NC

11
Exercise 11: Actuation of a sliding door
Solutions
Exercise 11: Actuation of a sliding door
Name: Date:
Initial position
The cylinder is in the retracted end position. The pneumatic proximity sensor 1B1 is attenuated.
A pneumatic signal is applied at one input of dual pressure valve 1V2.
Steps 1-2
The shuttle valve 1V1 supplies an output signal if one of the two pushbuttons is actuated. A
signal is now applied at pilot port 14 of the 5/2-way double pilot valve and the valve switches.
The cylinder advances.
When the cylinder reaches the forward end position, the pneumatic proximity sensor 1B2 is
attenuated.
Steps 2-3
The shuttle valve 1V1 supplies an output signal if one of the two pushbuttons is actuated. A
signal is now applied at pilot port 12 of the 5/2-way double pilot valve. The valve switches and
the cylinder advances. The pneumatic proximity sensors 1B1 is attenuated when the cylinder
reaches the retracted end position.
1 Cylinder, double-acting 1,Manifold
2 One-way flow control valve 1,Start-up valve with filter control valve
1 5/2-way double pilot valve, pneumatic 1,Compressed air supply
2 Proximity sensor, pneumatic 1,Manifold
2 Dual pressure valve (AND)

12
Exercise 12: Feeding of workpieces
Solutions
Name: Date:
Initial position
Compressed air is available. The cylinder is in the retracted end position. The pneumatic
proximity sensor 1B1 is attenuated and switched in free-flow direction. The piston rod chamber
is pressurized.
Steps 1-2
The 3/2-way valve 1S2 is not actuated unless the withdrawal area is free. The dual pressure
valve 1V1 does not supply an output signal, the 5/2-way double pilot valve cannot be reversed.
The 3/2-way valve 1S2 is actuated if the withdrawal area is free. The dual pressure valve 1V1
supplies an output signal. If the pushbutton of the 3/2-way valve 1S1 is actuated, the dual
pressure valve 1V2 supplies an output signal and a signal is applied at pilot port 14 of the 5/2-
way double pilot valve. The 5/2-way double pilot valve reverses and the cylinder advances.
Steps 2-3
The pneumatic proximity sensor 1B2 is attenuated and switches in the free-flow direction. A
signal is applied at pilot port 12 of the 5/2-way double pilot valve. The 5/2-way double pilot
valve 1V3 reverses and the cylinder moves into the retracted end position. The pneumatic limit
switch 1B1 is attenuated and switches in the free- flow direction.
Steps 3-1 Same as step 1

13
Solutions
Name: Date:
1 5/2-way double pilot valve, pneumatic
2 Proximity sensor, pneumatic
1 Manifold

14
Exercise 13: Crushing of drinks cans
Exercise 13: Crushing of drinks cans Solutions
Name: Date:
Initial position
The double-acting cylinder is in the retracted end position. The pneumatic proximity sensor 1B1
is actuated and switched to free-flow direction. Compressed air is available. The required
pressure is preset at the pressure regulating valve of the service unit. The required pressure is
set at the pressure sequence valve.
Steps 1-2 :The pushbutton of valve 1S1 is actuated whereby the condition at the dual pressur
valve (AND) 1V3 becomes true. The 5/2-way double pilot valve 1V5 is switched in the operating
position and the double-acting cylinder advances.
Steps 2-3 : The pneumatic proximity sensor 1B2 is actuated and switches into the operating
position. The 5/2-way double pilot valve 1V5 is reversed via the shuttle valve (OR) 1V4.
Alternatively, this process can be initiated via the pushbutton of valve 1S2. The 5/ way double
pilot valve is reversed via the shuttle valve (OR) 1V4. The double-acting cylinder moves into the
initial position and the process is completed when the pneumatic proximity sensor 1B1 is
actuated.
1 Cylinder, double-acting 1 Compressed air supply
1 Shuttle valve (OR)and (1)Manifold
1 Pressure sequence valve
1 Pressure regulating valve

15
Exercise 14: Packaging of brochures
Solutions
Name: Date:
Initial position
The double-acting cylinder is in the retracted end position. The pneumatic limit switch
1B1 is attenuated and switched in free-flow direction. Compressed air is available. The
desired pressure is preset at the pressure regulating valve of the service unit, the
pressure sequence valve and at the pressure regulating valve in the cylinder supply air.
Steps 1-2
Pushbutton valve 1S1 is actuated and switches in the free-flow direction. The pneumatic
proximity sensor 1B1 is switched to operating position and consequently the condition at
the dual pressure valve (AND) 1V3 becomes true and the 5/2-way double pilot valve 1V4
is switched to operating position. The double-acting cylinder advances pressure
regulated.
Steps 2-3
Pushbutton 1S2 is actuated and switches in free-flow direction. This causes the 5/2-way
double pilot valve to reverse. The double-acting cylinder returns to the initial position.
The process is completed if the pneumatic proximity sensor 1B1 is attenuated.

16
Solutions
Name: Date:
1 5/2-way double-pilot valve, pneumatic
1 Manifold

17
Exercise 15: Fitting of locking clips
Solutions
Name: Date:
Initial position
The double-acting cylinder is in the retracted end position. The pneumatic proximity sensor
1B1 is attenuated. Compressed air is available. The required pressure is set at the pressure
regulating valve and pressure sequence valve.
Steps 1-2
Pushbutton 1S1 is actuated and the pneumatic proximity sensor 1B1 is attenuated,
consequently the condition at the first dual pressure valve (AND) 1V3 becomes true. When the
pressure sequence valve has switched with sufficient pressure, the 3/2-way valve is switched
into the operating position. The condition at the second two-way valve (AND) 1V5
consequently becomes true and the 5/2-way double pilot valve switches reverses into the
operating position. The double-acting cylinder advances.
Steps 2-3
The pneumatic proximity sensor 1B2 is attenuated and switches into the operating position.
The 5/2-way double pilot valve is reversed. The double-acting cylinder returns into the initial
position. The process is completed if the pneumatic proximity sensor 1B1 is attenuated.

18
Solutions
Name: Date:
1 3/2-way valve, pneumatic, normally open
1 Manifold

19
Exercise 16: Labelling of paint pots
Solutions
Name: Date:
Initial position
The double-acting cylinder is in the retracted end position. The pneumatic proximity sensor 1B1
is attenuated. Compressed air is available. The desired pressure is set at the pressure regulating
valve.
Steps 1-2
Pushbutton 1S1 is actuated and the pneumatic proximity sensor 1B1 is attenuated;
consequently the condition at the first dual pressure valve (AND) 1V2 becomes true and the
5/2-way double pilot valve 1V4 switches into the operating position. The double-acting cylinder
advances using minimal pressure.
Steps 2-3
The pneumatic proximity sensor 1B2 is attenuated and switches into the operating position.
This causes compressed air to be supplied to the time delay valve 1V3 and to switch after a
preset time interval. The 5/2-way pilot valve is switched back and the double-acting cylinder
returns to the initial position using minimal pressure. The piston chamber is exhausted via the
quick exhaust valve. The process is completed if the pneumatic proximity sensor 1B1 is
attenuated.

20
Solutions
Name: Date:
1 Quick exhaust valve
1 Time delay valve
1 Pressure regulating valve with pressure gauge
1 Pressure gauge
1 Manifold

21
Exercise 17: Cleaning of workpieces
Solutions
Name: Date:
Initial position
The cylinder assumes the retracted end position in the initial position and actuates the 3/2-way
roller lever valve 1B1. The control element 1V4 (5/2-way double pilot valve) assumes the
righthand switching position. The signal latch 1V2 (3/2-way double pilot valve) is also in the
righthand switching position. The desired pressure is set at the pressure regulating valve.
Steps 1-2
Actuation of START button 1S1 causes the signal latch 1V2 to switch. Compressed air is applied
at the input of the time delay valve 1V1. The 5/2-way double pilot valve 1V4 is reversed via the
actuated 3/2-way roller lever valve 1B1 and the shuttle valve (OR) 1V3; the cylinder advances.
Overtravelling of the middle pneumatic proximity sensor 1B3 has no effect since the same pilot
input of the control element is actuated.
Steps 2-3
The pneumatic proximity sensor 1B2 is actuated in the forward end position. The control
element (5/2-way double solenoid valve) reverses. The cylinder partially retracts and actuates
the middle pneumatic proximity sensor 1B3.

22
Solutions
Name: Date:
Steps 3-4
Actuation of the middle pneumatic proximity sensor causes the cylinder to reverse again. The
switching function takes only a few milliseconds so that the switching
cam does not over travel the pneumatic proximity sensor 1B3.
Steps 4-5
See steps 2-3.
1 3/2-way roller lever valve, normally closed
1 3/2-way valve with pushbutton, normally close
1 Time delay valve
1 Manifold

23
Exercise 18: Pressing in of lids
Solutions
Name: Date:
Initial position
Pressure is available. Both cylinders assume the retracted end position in the initial position.
The piston of the double-acting cylinder attenuates the pneumatic proximity sensor (2B1); this
switches in free-flow direction. The control elements 1V2 and 2V1 (5/2-way double pilot valve
and 3/2-way double pilot valve) assume the right-hand switching position.
Steps 1-2
Actuation of pushbutton 1S1 causes the condition at the dual pressure valve (AND) 1V1 to
become true. The 3/2-way double pilot valve 1V2 reverses. The single-acting cylinder advances
with supply air restricted.
Steps 2-3
Roller lever valve 1B2 is actuated when the single-acting cylinder reaches is forward end
position and switches the 5/2-way double pilot valve 2V1. The double-acting cylinder advances
into the forward end position, where it attenuates the pneumatic proximity sensor 2B2. This
switches to free-flow direction.
Steps 3-4
The 5/2-way double pilot valve 2V1 and 3/2-way double pilot valve 1V2 reverse. Both cylinders
retract. The process is completed when the piston of the double- acting cylinder attenuates the
pneumatic proximity sensor (2B1) and this switches in free-flow direction.
.

24
Solutions
Name: Date:
Compile the equipment list by entering the required equipment in the table below
1 3/2-way roller lever valve, normally closed
1 Manifold

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