basic pneumatic circuitry for control and automation
TRANSCRIPT
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Basic Pneumatic Circuitry
For control and automation
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Contents
Symbols Circuit layout Actuator control 2/2 Valve Actuator control 3/2 Valve Actuator control 5/2 Valve
Sequence solution 5/3 Valves Poppet/spool logic Balanced spool logic Feedback
Sequential control
Click the section to advance directly to it
Introduction
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Introduction
This module shows the methods of application of pneumatic valves and components for control and automation
The methods of pure pneumatic sequential control are confined to simple examples
The majority of modern systems are controlled electronically and is the subject of electro-pneumatic modules
A message to pneumatic circuit designers:
Use proven and reliable design techniques
Produce circuits and documentation that are clear to read
Design for safety Do not try to be too
clever, the circuit will be difficult for others to read and maintain
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Symbols
The standard for fluid power symbols is ISO 1219-1. This is a set of basic shapes and rules for the construction of fluid power symbols
Cylinders can be drawn to show their extreme or intermediate positions of stroke and any length above their width
Valves show all states in the one symbol. The prevailing state is shown with the port connections
Other components are single state symbols
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Symbols single acting actuators
Single acting, sprung instroked
Single acting, sprung outstroked
Single acting, sprung instroked, magnetic
Single acting, sprung outstroked, magnetic
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Symbols double acting actuators
Double acting, non-cushioned
Double acting, adjustable cushions
Double acting, through rod, adjustable cushions
Double acting, magnetic, adjustable cushions
Double acting, rodless, magnetic, adjustable cushions
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Symbols rotary actuators
Semi-rotary double acting Rotary motor single
direction of rotation Rotary motor bi-
directional
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Symbols valves
2/2 Valve push button / spring
3/2 Valve push button / spring
3/2 Valve detented lever operated
2
13
12 10
21012
1
1
2
312
10
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Symbols valves
3/2 Valve differential pressure operated
5/2 Valve push button / spring
5/3 Valve double pressure operated spring centre
1
24
5 3
14 12
1
24
5 3
1
2
3
12 10
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Symbols valves A valve function is known by a pair of numbers e.g. 3/2. This
indicates the valve has 3 main ports and 2 states The valve symbol shows both of the states Port numbering is to CETOP RP68P and shows:
when the valve is operated at the 12 end port 1 is connected to port 2 when reset to the normal state at the 10 end port 1 is connected to
nothing (0)
2
13
12 10
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Symbols valves A valve function is known by a pair of numbers e.g. 3/2. This
indicates the valve has 3 main ports and 2 states The valve symbol shows both of the states Port numbering is to CETOP RP68P and shows:
when the valve is operated at the 12 end port 1 is connected to port 2 when reset to the normal state at the 10 end port 1 is connected to
nothing (0)
2
13
12 10
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Symbols valves
This example is for a 5/2 valve
This has 5 main ports and 2 states
When the valve is operated at the 14 end port 1 is connected to port 4 (also port 2 is connected to port 3)
When reset to the normal state at the 12 end port 1 is connected to port 2 (also port 4 is connected to port 5)
1
24
5 3
14 12
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Symbols valves
This example is for a 5/2 valve
This has 5 main ports and 2 states
When the valve is operated at the 14 end port 1 is connected to port 4 (also port 2 is connected to port 3)
When reset to the normal state at the 12 end port 1 is connected to port 2 (also port 4 is connected to port 5)
1
24
5 3
14 12
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Symbols operators manual
General manual
Push button
Pull button
Push/pull button
Lever
Pedal
Treadle
Rotary knob
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Symbols operators mechanical
Plunger
Spring normally as a return
Roller
Uni-direction or one way trip
Pressure
Pilot pressure
Differential pressure
Detent in 3 positions
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Symbols 5/3 valves
All valves types shown in the normal position
Type 1. All ports blocked
Type 2. Outlets to exhaust
Type 3. Supply to outlets
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Symbols function components
Non-return valve 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
* Note: Traditional symbol in extensive use (preferred)
*
ISO 1219-1 Old
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Symbols air line equipment
Water separator with automatic drain
Filter with manual drain Filter with automatic drain Filter with automatic drain
and service indicator Lubricator Pressure regulator with
gauge F.R.L. filter, regulator,
lubricator simplified symbol
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Circuit layout
The standard for circuit diagrams is ISO 1219-2
A4 format or A3 folded to A4 height for inclusion in a manual with other A4 documentation
To be on several sheets if necessary with line identification code
Minimum crossing lines Limit valves position of
operation by actuators shown by a marker with reference code to symbol
Circuits should be drawn with all actuators at the top of the page in order of sequential operation
Other components to be drawn in sequential order from the bottom up and from left to right
Circuit should show the system with pressure applied and ready to start
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Component identification
The ISO suggested component numbering system is suited for large circuits and those drawn on several pages
For this presentation a simple code is used
For cylinders: A,B,C etc. For associated feedback
valves: alpha-numeric code ‘a0’ for proof of instroke, ‘a1’ for proof of outstroke
For cylinder B: b0 and b1
A
a0 a1
1
2
3
12 10
a0
2
13
12 10
a1
Note: the a0 valve symbol is drawn in the operated position because the actuator A is instroked
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Example circuit
Run/End
Aa0 a1
Bb0 b1
Cc0 c1
a0 a1 b0b1 c0c1
10 bar max 6 barTo all inlet ports marked
SequenceRun/EndA+B+B-C+C-A-Repeat
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Actuator control 2/2 valve
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2/2 Valve actuator control
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
21012
1
11012
2OUT IN
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2/2 Valve actuator control
The button marked OUT is pushed to operate the valve
Air is connected to the cylinder and it outstrokes
Air cannot escape to atmosphere through the valve marked IN as this is closed
The air at atmospheric pressure in the front of the cylinder vents through the breather port
210
1
1211012
2OUT IN
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2/2 Valve actuator control
The push button of the valve marked OUT is released and it returns to a normal closed position
Air is now trapped in the system and provided there are no leaks the piston rod will stay in the outstroked position
If the load increases beyond the force exerted by the air the piston rod will start to move in
210
1
1211012
2OUT IN
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2/2 Valve actuator control
The button marked IN is pushed to operate the valve
Air escapes and the piston rod moves to the instroked position
The push button must be held operated until the piston rod is fully in
Atmospheric air will be drawn in to the front of the cylinder through the vent port
210
1
121
2
1012
OUT IN
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2/2 Valve actuator control
If the button marked IN is released the piston rod will remain in the instroked position
Any leaks in the installation can cause the piston rod to creep
210
1
121
2
1012
OUT IN
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2/2 Valve actuator control
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
1012 1012
OUT IN
2
1
1
2
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2/2 Valve actuator control
By repeated operation of either button during movement the piston rod can be moved in small steps for approximate positioning
This will only be successful under slow speeds
1012 1012
OUT IN
2
1
1
2
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2/2 Valve actuator control
With any compressed air system that intentionally traps air, the potential hazard of this must be recognised
Unintended release or application of pressure can give rise to unexpected movement of the piston rod
A pressure indicator or gauge must be fitted to warn of the presence of pressure
210
1
121
2
1012
OUT IN
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Actuator control 3/2 valve
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3/2 valve actuator control
A 3 port valve provides the inlet and exhaust path and is the normal choice for the control of a single acting cylinder
In the normal position produced by the spring, the valve is closed
In the operated position produced by the push button the valve is open
The push button must be held down for as long as the cylinder is outstroked
1
2
3
12 10
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3/2 valve actuator control
A 3 port valve provides the inlet and exhaust path and is the normal choice for the control of a single acting cylinder
In the normal position produced by the spring, the valve is closed
In the operated position produced by the push button the valve is open
The push button must be held down for as long as the cylinder is outstroked
1
2
3
12 10
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3/2 valve actuator control
A 3 port valve provides the inlet and exhaust path and is the normal choice for the control of a single acting cylinder
In the normal position produced by the spring, the valve is closed
In the operated position produced by the push button the valve is open
The push button must be held down for as long as the cylinder is outstroked
1
2
3
12 10
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3/2 valve actuator control
To generally slow the cylinder speed an adjustable bi-directional flow regulator or fixed restrictor can be used
The flow regulator setting will be a compromise as the ideal outstroke speed may not produce the desired results for the instroke speed
1
2
3
12 10
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3/2 valve actuator control
To control the outstroke speed of a single acting cylinder without controlling the instroke speed, a uni-directional flow regulator is used
The flow into the cylinder closes the non return valve and can only pass through the adjustable restrictor
By adjusting the restrictor the outstroke speed of the cylinder can be set
1
2
3
12 10
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3/2 valve actuator control
For independent speed control in each direction two flow regulators are required
Installed in opposite directions to each other
Upper regulator controls the outstroke speed
Lower regulator controls the instroking speed 1
2
3
12 10
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3/2 valve actuator control
A 3 port valve provides the inlet and exhaust path and is the normal choice for the control of a single acting cylinder
In the normal position produced by the spring, the valve is closed
In the operated position produced by the push button the valve is open
The push button must be held down for as long as the cylinder is outstroked
1
2
3
12 10
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Actuator control 5/2 valve
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5/2 Valve actuator control
For a double acting cylinder the power and exhaust paths are switched simultaneously
When the button is pushed the supply at port 1 is connected to port 4 and the outlet port 2 connected to exhaust port 3. The cylinder moves plus
When the button is released port 1 is connected to port 2 and port 4 connected to port 5. Cylinder minus
1
24
5 3
14 12
+-
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5/2 Valve actuator control
For a double acting cylinder the power and exhaust paths are switched simultaneously
When the button is pushed the supply at port 1 is connected to port 4 and the outlet port 2 connected to exhaust port 3. The cylinder moves plus
When the button is released port 1 is connected to port 2 and port 4 connected to port 5. Cylinder minus
1
24
5 3
14 12
+-
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5/2 Valve actuator control
Independent speed control of the plus and minus movements
In most applications speed is controlled by restricting air out of a cylinder
Full power is developed to drive the piston with speed controlled by restricting the back pressure
1
24
5 3
14 12
+-
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5/2 Valve actuator control
Independent speed control of the plus and minus movements
In most applications speed is controlled by restricting air out of a cylinder
Full power is developed to drive the piston with speed controlled by restricting the back pressure
1
24
5 3
14 12
+-
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5/2 Valve actuator control
Valves with a spring return are mono-stable and need the operator to be held all the time that the cylinder is required in the plus position
Bi-stable valves will stay in the position they were last set
The lever valve example illustrated indicates a detent mechanism. The lever need not be held once the new position has been established
1
24
5 314 12
+-
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Manual control
Remote manual control of a double acting cylinder
Valve marked + will cause the cylinder to outstroke or move plus
Valve marked - will cause the cylinder to instroke or move minus
The 5/2 double pilot valve is bi-stable therefore the push button valves only need to be pulsed
1
24
5 3
14 12
1
2
3
12 10
1
2
3
12 10
+ -
+-
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Manual control
Remote manual control of a double acting cylinder
Valve marked + will cause the cylinder to outstroke or move plus
Valve marked - will cause the cylinder to instroke or move minus
The 5/2 double pilot valve is bi-stable therefore the push button valves only need to be pulsed
1
24
5 3
1
2
3
12 10
1
2
3
12 10
14 12
+ -
+-
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Manual control
Remote manual control of a double acting cylinder
Valve marked + will cause the cylinder to outstroke or move plus
Valve marked - will cause the cylinder to instroke or move minus
The 5/2 double pilot valve is bi-stable therefore the push button valves only need to be pulsed
1
24
5 3
1
2
3
12 10
1
2
3
12 10
14 12
+ -
+-
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Manual control
Remote manual control of a double acting cylinder
Valve marked + will cause the cylinder to outstroke or move plus
Valve marked - will cause the cylinder to instroke or move minus
The 5/2 double pilot valve is bi-stable therefore the push button valves only need to be pulsed
1
24
5 3
14 12
1
2
3
12 10
1
2
3
12 10
+ -
+-
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Manual control
Remote manual control of a double acting cylinder
Valve marked + will cause the cylinder to outstroke or move plus
Valve marked - will cause the cylinder to instroke or move minus
The 5/2 double pilot valve is bi-stable therefore the push button valves only need to be pulsed
1
24
5 3
14 12
1
2
3
12 10
1
2
3
12 10
+ -
+-
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Semi-automatic control
Manual remote start of a double acting cylinder with automatic return
Cylinder identified as “A” Trip valve operated at the
completion of the plus stroke identified as “a1”
1
24
5 3
14 12
1
2
3
12 10
1
2
3
12 10
+ -
+-
A
a1
a1
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Fully-automatic control
Continuous automatic cycling from roller operated trip valves
Manual Run and End of the automatic cycling
Cylinder will come to rest in the instroked position regardless of when the valve is put to End
Tags for the roller feedback valves a0 and a1 show their relative positions
1
24
5 3
14 12
2
13
12 10
1
2
3
12 10
1
2
312
10
Run/End
+-
A
a0 a1
a0 a1
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Sequential control
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Circuit building blocks
These circuits can be considered as building blocks for larger sequential circuits consisting of two or more cylinders
Each actuator will have a power valve and two associated feedback valves. The first actuator to move also hasa Run/End valve
Run/End
A Ba0 a1 b0 b1
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Repeat pattern sequence
A repeat pattern sequence is one where the order of the movements in the first half of the sequence is repeated in the second half
Each actuator may have one Out and In stroke only in the sequence
There may be any number of actuators in the sequence
The signal starting the first movement must pass through the Run/End valve
Needs only the basic building blocks to solve
Examples of repeat pattern sequences:
A+ B+ C+ D+ A- B- C- D- A- B+ C- A+ B- C+ C+ A+ B- C- A- B+
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Repeat pattern sequence
The two cylinders A and B are to perform a simple repeat pattern sequence as follows: A+ B+ A- B-
Apply the rule “The signal given by the completion of each movement will initiate the next movement”
In this way the roller valves can beidentified and labelled
Run/End
A B
a0a1b0 b1
a0 a1 b0 b1
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Repeat pattern sequence
For three cylinders A, B and C also to perform a simple repeat pattern sequence as follows: A+ B+ C+ A- B- C-
Apply the rule “The signal given by the completion of each movement will initiate the next movement”
Run/End
A
c0 c1
a0 a1
B
a0a1
b0 b1
C
b0b1
c0 c1
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Non-repeat pattern sequence
If the rule applied to a repeat pattern sequence is applied to any other sequence there will be opposed signals on one or more of the 5/2 valves preventing operation
This circuit demonstrates the problem The sequence is A+ B+ B- A-
Run/End
A B
b1a1a0 b0
a0 a1 b0 b1
![Page 58: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/58.jpg)
Opposed signals
When the valve is set to Run, cylinder A will not move because the 5/2 valve has an opposed signal, it is still being signalled to hold position by the feedback valve b0
If A was able to move + a similar problem will occur for the 5/2 valve of B once it was +
The sequence is A+ B+ B- A-
Run/End
A B
b1a1a0 b0
a0 a1 b0 b1
![Page 59: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/59.jpg)
Mechanical solution
The problem was caused by valves b0 and a1 being operated at the time the new opposing instruction is given
If these two valves were “one way trip” types and over tripped at the last movement of stroke, only a pulse wouldbe obtained instead of a continuous signal
Run/End
A B
b1a1a0
a0 a1 b0 b1
b0
![Page 60: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/60.jpg)
Sequence solution methods
The main solutions to solving sequences are:
Cascade (pneumatic) Shift register (pneumatic) Electro-pneumatic PLC (Programmable
logic controller) Cascade circuits provide
a standard method of solving any sequence. It uses a minimum of additional logic hardware (one logic valve per group of sequential steps)
Shift register circuits are similar to cascade but use one logic valve for every step
Electro-pneumatic circuits use solenoid valves and electro-mechanical relays
PLC. The standard solution for medium to complex sequential systems (except where electrical equipment cannot be used)
![Page 61: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/61.jpg)
Cascade two group
The A+ B+ B- A- circuit is solved by the two group cascade method
The sequence is divided at the point where B immediately returns
The two parts are allocated groups l and ll
Gp l A+ B+ / Gp ll B- A- Two signal supplies are
provided from a 5/2 valve one is available only in group l the other is available only in group ll
Because only one group output is available at a time it is not possible to have opposed signals
A standard 5/2 double pressure operated valve is the cascade valve
1
24
5 3
14 12
Group l Group ll
Select l Select ll
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Cascade (two group)A B
a1
b0
a0 a1 b0 b1
Run/End
a0 b1
SequenceGp l A+ B+ Gp ll B- A-
Gp l
Gp ll
![Page 63: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/63.jpg)
Cascade (two group)A B
a1
b0
a0 a1 b0 b1
Run/End
a0 b1
SequenceGp l A+ B+ Gp ll B- A-
Gp l
Gp ll
![Page 64: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/64.jpg)
Cascade (two group)A B
b0
a0 a1 b0 b1
Run/End
a1
a0 b1
SequenceGp l A+ B+ Gp ll B- A-
Gp l
Gp ll
![Page 65: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/65.jpg)
Cascade (two group)A B
b0
a0 a1 b0 b1
Run/End
a1
a0 b1
SequenceGp l A+ B+ Gp ll B- A-
Gp l
Gp ll
![Page 66: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/66.jpg)
Cascade (two group)A B
a0 a1 b0 b1
Run/End
a1
a0
SequenceGp l A+ B+ Gp ll B- A-
Gp l
Gp ll
b0
b1
![Page 67: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/67.jpg)
Cascade (two group)A B
a0 a1 b0 b1
Run/End
SequenceGp l A+ B+ Gp ll B- A-
Gp l
Gp ll
b0
b1
a1
a0
![Page 68: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/68.jpg)
Cascade building blocks
A two group building block consists of a lever valve to run and end the sequence plus the 5/2 double pilot operated cascade valve
For a two group system consisting of any number of cylinders this building block and the cylinder building blocks are all that is required to solve the sequence
1
24
5 3
14 12
1
2
312
10
Gp l
Gp ll
Sel l
Sel llRun/End
![Page 69: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/69.jpg)
Cascade building blocks
Gp l
Gp llSel lSel ll
Gp lll
Sel lll
Run/End
This three group building block establishes an interconnecting pattern that can be extended to any number of groups
![Page 70: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/70.jpg)
Dual trip building blocks
When a sequence has a cylinder operating twice in one overall sequence a dual trip building block may be required for each of the two feedback valves
The supply will be from different groups and the output go to different destinations
Example is for feedback valve a1 of cylinder A when A is sent + both in Group x and Group y
Send A+
A+ inGroup x
A+ inGroup y
a1
a1 in x
a1 in y
Note: can often be rationalised to lessthan these three components
![Page 71: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/71.jpg)
Cascade rules
Establish the correct sequence
Divide the sequence in to groups. Always start a sequence with the Run/End valve selecting group l e.g. R/E | A+ B+ | B- C+ | C- A-
Select the cylinder building blocks
Select the cascade building block
Select dual trip building blocks if required
Interconnect the blocks as follows:
The first function in each group is signalled directly by that group supply
The last trip valve operated in each group is supplied with main supply air and selects the next group
The remaining trip valves are supplied with air from their respective groups and initiate the next function
The “run/end” valve will control the signal from the last trip valve to be operated
![Page 72: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/72.jpg)
Three position valves
![Page 73: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/73.jpg)
5/3 Valve
5/3 valves have a third mid position
The valve can be tri-stable e.g. a detented lever operator or mono-stable e.g. a double air or double solenoid with spring centre
There are three common configurations for the mid position:
All ports blocked Centre open exhaust Centre open pressure
The majority of applications are actuator positioning and safety
24
15 314 12
14 1224
15 3
14 1224
15 3
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5/3 Valve actuator control
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
24
15 314 12
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5/3 Valve actuator control
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
24
15 314 12
![Page 76: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/76.jpg)
5/3 Valve actuator control
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
24
15 314 12
![Page 77: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/77.jpg)
5/3 Valve actuator control
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
24
15 314 12
![Page 78: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/78.jpg)
5/3 Valve actuator control
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
24
15 314 12
![Page 79: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/79.jpg)
5/3 Valve actuator control
This version of a 5/3 valve is “centre open exhaust”
The supply at port 1 is isolated and the cylinder has power exhausted when this centre position is selected
The version illustrated shows a mono-stable version double pilot operated spring centre
The cylinder will be pre-exhausted when changing from the mid position
24
15 3
14 12
![Page 80: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/80.jpg)
5/3 Valve actuator control
This version of a 5/3 valve is “centre open pressure”
The supply at port 1 is connected to both sides of the cylinder and the exhaust ports isolated when this centre position is selected
Can be used to balance pressures in positioning applications
The version illustrated is mono-stable, double solenoid, spring centre
1
24
5 3
14 12
![Page 81: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/81.jpg)
Logic functions for poppet and spool valves
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Logic AND
To obtain the output Z both plungers X AND Y must be operated and held
If X only is operated the air will be blocked at port 1 in valve Y
If Y only is operated there will be no pressure available at port 1
If either X or Y is released the output signal Z will be lost
1
2
3
12 10
1
2
3
12 10X
Y
Z
![Page 83: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/83.jpg)
Logic AND
To obtain the output Z both plungers X AND Y must be operated and held
If X only is operated the air will be blocked at port 1 in valve Y
If Y only is operated there will be no pressure available at port 1
If either X or Y is released the output signal Z will be lost
1
2
3
12 10
1
2
3X
Y
Z
12 10
![Page 84: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/84.jpg)
Logic AND
To obtain the output Z both plungers X AND Y must be operated and held
If X only is operated the air will be blocked at port 1 in valve Y
If Y only is operated there will be no pressure available at port 1
If either X or Y is released the output signal Z will be lost
1
2
3
12 10
1
2
3
12 10X
Y
Z
![Page 85: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/85.jpg)
Logic AND
To obtain the output Z both plungers X AND Y must be operated and held
If X only is operated the air will be blocked at port 1 in valve Y
If Y only is operated there will be no pressure available at port 1
If either X or Y is released the output signal Z will be lost
1
2
3
1
2
3
12 10X
Y
Z
12 10
![Page 86: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/86.jpg)
Logic AND
To obtain the output Z both plungers X AND Y must be operated and held
If X only is operated the air will be blocked at port 1 in valve Y
If Y only is operated there will be no pressure available at port 1
If either X or Y is released the output signal Z will be lost
1
2
3
1
2
3X
Y
Z
12 10
12 10
![Page 87: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/87.jpg)
Logic AND
To obtain the output Z both plungers X AND Y must be operated and held
If X only is operated the air will be blocked at port 1 in valve Y
If Y only is operated there will be no pressure available at port 1
If either X or Y is released the output signal Z will be lost
1
2
3
1
2
3
12 10X
Y
Z
12 10
![Page 88: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/88.jpg)
Logic AND
To obtain the output Z both plungers X AND Y must be operated and held
If X only is operated the air will be blocked at port 1 in valve Y
If Y only is operated there will be no pressure available at port 1
If either X or Y is released the output signal Z will be lost
1
2
3
12 10
1
2
3
12 10X
Y
Z
![Page 89: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/89.jpg)
Logic AND
This method must not be used as a two handed safety control
It is too easy to abuse. e.g. one of the buttons could be permanently fixed down and the system operated from the other button only
Use the purpose designed two handed safety control unit
1
2
3
12 10
1
2
3
12 10X
Y
Z
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Logic OR
Use of an ‘OR’ function shuttle valve
Source X and Y can be remote from each other and remote from the destination of Z
When X or Y is operated the shuttle valve seal moves across to prevent the signal Z from being lost through the exhaust of the other valve
X
Y
Z
1
2
3
12 10
1
2
3
12 10
![Page 91: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/91.jpg)
Logic OR
Use of an ‘OR’ function shuttle valve
Source X and Y can be remote from each other and remote from the destination of Z
When X or Y is operated the shuttle valve seal moves across to prevent the signal Z from being lost through the exhaust of the other valve
X
Y
Z
1
2
3
12 10
1
2
3
12 10
![Page 92: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/92.jpg)
Logic OR
Use of an ‘OR’ function shuttle valve
Source X and Y can be remote from each other and remote from the destination of Z
When X or Y is operated the shuttle valve seal moves across to prevent the signal Z from being lost through the exhaust of the other valve
X
Y
Z
1
2
3
12 10
1
2
3
12 10
![Page 93: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/93.jpg)
Logic OR
Use of an ‘OR’ function shuttle valve
Source X and Y can be remote from each other and remote from the destination of Z
When X or Y is operated the shuttle valve seal moves across to prevent the signal Z from being lost through the exhaust of the other valve
X
Y
Z
1
2
3
12 10
1
2
3
12 10
![Page 94: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/94.jpg)
Logic OR
Use of an ‘OR’ function shuttle valve
Source X and Y can be remote from each other and remote from the destination of Z
When X or Y is operated the shuttle valve seal moves across to prevent the signal Z from being lost through the exhaust of the other valve
X
Y
Z
1
2
3
12 10
1
2
3
12 10
![Page 95: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/95.jpg)
Logic NOT
A logic NOT applies to the state of the output when the operating signal is present (the output is simply an inversion of the operating signal)
The valve shown is a normally open type (inlet port numbered 1)
When the signal X is present there is NOT output Z
When X is removed output Z is given
2
31
12 10
Z
X
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Logic NOT
A logic NOT applies to the state of the output when the operating signal is present (the output is simply an inversion of the operating signal)
The valve shown is a normally open type (inlet port numbered 1)
When the signal X is present there is NOT output Z
When X is removed output Z is given
2
31
12 10
Z
X
![Page 97: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/97.jpg)
Logic NOT
A logic NOT applies to the state of the output when the operating signal is present (the output is simply an inversion of the operating signal)
The valve shown is a normally open type (inlet port numbered 1)
When the signal X is present there is NOT output Z
When X is removed output Z is given
2
31
12 10
Z
X
![Page 98: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/98.jpg)
Logic MEMORY
A logic MEMORY allows the output signal state (ON or OFF) to be maintained after the input signal has been removed
Any bi-stable valve is a logic MEMORY
With this lever detented valve, once the lever has been moved X direction or Y direction it can be released and will stay in that position
Z
X
1310
Y12
![Page 99: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/99.jpg)
Logic MEMORY
A logic MEMORY allows the output signal state (ON or OFF) to be maintained after the signal that set it has been removed
Z
X13
12 10 Y
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Logic MEMORY
A bi-stable double pilot valve can be set or reset simply by a pulse (push and release) on buttons X or Y
Z
13
X
Y1
2
3
12 10
1
2
3
12 10
12 10
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Logic MEMORY
A bi-stable double pilot valve can be set or reset simply by a pulse (push and release) on buttons X or Y
Z
13
X
Y1
2
3
12 10
1
2
3
12 10
12 10
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Logic MEMORY
A bi-stable double pilot valve can be set or reset simply by a pulse (push and release) on buttons X or Y
Z
13
X
Y1
2
3
12 10
1
2
3
12 10
12 10
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Logic MEMORY
A bi-stable double pilot valve can be set or reset simply by a pulse (push and release) on buttons X or Y
Z
13
X
Y1
2
3
12 10
1
2
3
12 10
12 10
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Logic MEMORY
A bi-stable double pilot valve can be set or reset simply by a pulse (push and release) on buttons X or Y
Z
13
X
Y1
2
3
12 10
1
2
3
12 10
12 10
![Page 105: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/105.jpg)
Logic MEMORY (latch)
A popular memory circuit is the latch
Will not re-make after pneumatic power failure
A pulse on X operates the pilot / spring valve to give output Z
A feedback from Z runs through the normally open valve Y to latch the operation of Z when X is released
A pulse on Y breaks the latch and Z is exhausted
X
Y
Z
13
1
2
3
12 10
1012
3
2
1
12 10
![Page 106: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/106.jpg)
Logic MEMORY (latch)
A popular memory circuit is the latch
Will not re-make after pneumatic power failure
A pulse on X operates the pilot / spring valve to give output Z
A feedback from Z runs through the normally open valve Y to latch the operation of Z when X is released
A pulse on Y breaks the latch and Z is exhausted
X
Y
Z
13
1
2
3
12 10
12 10
3
2
1
12 10
![Page 107: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/107.jpg)
Logic MEMORY (latch)
A popular memory circuit is the latch
Will not re-make after pneumatic power failure
A pulse on X operates the pilot / spring valve to give output Z
A feedback from Z runs through the normally open valve Y to latch the operation of Z when X is released
A pulse on Y breaks the latch and Z is exhausted
X
Y
Z
13
1
2
3
12 10
12 10
3
2
1
12 10
![Page 108: Basic Pneumatic Circuitry For control and automation](https://reader035.vdocument.in/reader035/viewer/2022081501/56649c8f5503460f94948ffa/html5/thumbnails/108.jpg)
Logic MEMORY (latch)
A popular memory circuit is the latch
Will not re-make after pneumatic power failure
A pulse on X operates the pilot / spring valve to give output Z
A feedback from Z runs through the normally open valve Y to latch the operation of Z when X is released
A pulse on Y breaks the latch and Z is exhausted
X
Y
Z
13
1
2
3
12 10
3
2
1
12 10
12 10
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Logic MEMORY (latch)
A popular memory circuit is the latch
Will not re-make after pneumatic power failure
A pulse on X operates the pilot / spring valve to give output Z
A feedback from Z runs through the normally open valve Y to latch the operation of Z when X is released
A pulse on Y breaks the latch and Z is exhausted
X
Y
Z
13
1
2
3
12 10
3
2
1
12 10
12 10
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Logic arrangements for fully balanced spool valves
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Logic circuits (spool valves)
Selection / Diversion Latch OR, AND, NOT Single pulse maker Slow pressure build Pre-select
Single pulse control Air conservation Double flow Counting
5/2 OR
Click the section to advance directly to it
NO / NC
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3/2 NO / NC
A fully balanced valve allows pressure on any pot or combination of ports
A single valve can be used normally open or normally closed
For normally open the supply pressure is connected to port 1
For normally closed the supply pressure is connected to port 3
1
2
3
12 10
2
13
12 10
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3/2 NO / NC
A fully balanced valve allows pressure on any pot or combination of ports
A single valve can be used normally open or normally closed
For normally open the supply pressure is connected to port 1
For normally closed the supply pressure is connected to port 3
1
2
3
12 10
2
13
12 10
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3/2 Valve selection / diversion
Selection of one of two supplies connected to ports 1 and 3 can be different pressures
Diversion of one supply to one of two outlets
If it is required to exhaust the downstream air a 5/2 valve is required
1
2
3
12 10
2
13
12 10
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3/2 Valve selection / diversion
Selection of one of two supplies connected to ports 1 and 3 can be different pressures
Diversion of one supply to one of two outlets
If it is required to exhaust the downstream air a 5/2 valve is required
1
2
3
2
13
12 10
12 10
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Latch with controls
In this version of a latch the push button valves are connected to perform ‘OR’ and ‘NOT’ functions
The ‘OFF’ valve must be placed last in the signal chain so that if both valves are operated together the ‘OFF’ command will dominate over the ‘ON’ command
1
2
3
12 10
2
13
12 10
2
13
12 10
ON
OFF
Out
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OR, AND, NOT
A single 3/2 pilot operated spring return valve can be use for any of these logic functions
x OR y gives output z x AND y gives output z x gives NOT z
1
2
3
12 10
1
2
3
12 10
1
2
3
12 10
AND
OR
NOT
x y
z
x y
z
x
z
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Single pulse maker
Converts a prolonged signal x into a single pulse z
Signal z must be removed to allow the valve to reset then x can be applied again
The duration of the pulse can be adjusted with the flow regulator
1
2
3
12 10
x
z
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Slow initial pressure build up
Choose a 3/2 pilot spring valve with a relatively high operating force e.g. 3 to 4 bar
When the quick connect coupling is made, the output at port 2 is controlled at the rate of the flow regulator setting
When the pressure is high enough to operate the valve full flow will take over
1
2
3
12 10
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Pre-select
The lever valve can pre-select the movement of the cylinder OUT or IN
The movement will occur the next time the plunger valve is operated
The plunger valve can be released immediately and subsequently operated and released any number of times
1
2
3
12 10
1
2
3
12 10
1
2
312
10
OUT/INpre-select
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5/2 OR function
The valve at position ‘a’ is reversed connected and supplied from the valve conventionally connected at position ‘b’
The cylinder can be controlled from either position ‘a’ ‘OR’ position ‘b’
1
24
5 3
1412
1
24
5 3
1412
a
b
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Single pulse control
24
1412
1
2
3
12 10
15
12 10
1
2
3
2
13
1210
Each time the foot operated valve is pressed the cylinder will single stroke + and - alternately
First foot operation the cylinder moves out
Second foot operation the cylinder moves in
Third….. out and so on
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Air conservation
Power stroke in the instroke direction only
Differential area of the piston gives an outstroke force when the pressure is balanced
Air used to outstroke is equivalent to a cylinder with only the same bore as the rod diameter
Assumes the cylinder is not loaded on the plus stroke and low friction
24
15
1412
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Air conservation
Power stroke in the instroke direction only
Differential area of the piston gives an outstroke force when the pressure is balanced
Air used to outstroke is equivalent to a cylinder with only the same bore as the rod diameter
Assumes the cylinder is not loaded on the plus stroke and low friction
24
15
1412
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Double flow
Where a larger 3/2 valve is not available
Two flow paths in a 5/2 valve each with a separate supply can be arranged to give double flow or supply separate devices
Ensure the tube size to the cylinder is large enough to take the double flow
4 2
1 3
1214
5 1
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Double flow
Where a larger 3/2 valve is not available
Two flow paths in a 5/2 valve each with a separate supply can be arranged to give double flow or supply separate devices
Ensure the tube size to the cylinder is large enough to take the double flow
4 2
1 3
1214
5
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Counting
Counting applications are best achieved with electro-mechanical or programmable electronic counters
Pneumatic counting circuits use large numbers of logic valves and can be slow
The counting chain shown will count to 4
Red and blue are non-overlapping alternate pulses, purple is the reset line
1
2
3
4
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Counting application
The counting circuit is applied to count 4 strokes of a cylinder
At rest all counting valves are held reset by the start valve
Start outstrokes ‘A’ Alternate signals from ‘a1’
and ‘a0’ progresses operation of the counting valves up the chain
On the 4th operation of ‘a1’ the green signal resets the start valve to stop the cylinder
A
a0a1
a0 a1
Start
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Feedback methods
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Time delay
A signal is restricted to slow the rate of pressure build up on a pressure switch (3/2 differential pressure operated valve)
When the pressure switch operates a strong un-restricted output is given
A reservoir provides capacitance to allow less fine and sensitive settings on the flow regulator making it easy to adjust
1
2
3
12 10
Signalin
Output
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Time delay
Manual remote start of a double acting cylinder with a time delay in the outstroked position before automatic return
2
1
24
5 3
14 12
13
12 10
+-
A
a1
1
2
3
12 10
a1
1
2
3
12 10
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Pressure decay
Manual remote start of a double acting cylinder
Uses a low pressure operated valve connected normally open
When the back pressure in the front of the cylinder falls below 0.1 bar the return signal is given
Connection taken between the cylinder and flow regulator
Useful for pressing work pieces of variable size
1
24
5 3
14 12
2
13
12 10
+-
A
a1
21210
1 3 0.1bar
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Electro-pneumatic
The majority of systems use electrical/electronic control due to the high degree of sophistication and flexibility
Solenoid valves are used to control cylinders
Feedback signals are from reed switches, sensors and electrical limit switches
Logic is hard wired or programmed in to a PLC (programmable logic controller)
a0 a1
1
24
5 3
14 12
A
a0 a1
Circuit building block for each cylinder
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End