ME 434

Basic Hydraulic and Pneumatic Systems

By
Assoc. Prof. Hossam S.S. AbdelMeguid
Basic Pneumatic Systems
Contents
 Introduction  Sequential control

 Symbols  Sequence solution

 Circuit layout  5/3 Valves

 Actuator control 2/2 Valve  Poppet/spool logic

 Actuator control 3/2 Valve  Balanced spool logic

 Actuator control 5/2 Valve  Feedback

Click the section to advance directly to it

Actuators

• Actuators can be classified into three types.

1. Linear actuators: These devices convert hydraulic/pneumatic energy into
linear motion.
2. Rotary actuators: These devices convert hydraulic/pneumatic energy into
rotary motion.
3. Actuators to operate flow control valves: these are used to control the flow
and pressure of fluids such as gases, steam or liquid.
Single acting cylinder
Double acting cylinder
 Cylinder end cushions

Double acting cylinders generally contain

cylinder cushions at the end of the cylinder to
slow down the movement of the piston near the
end of the stroke.
rotary actuator
Vane motor Gear motor
 Limited rotation actuators

• It is used for double acting operation and

has a maximum angle of rotation of about
270°.
• These are generally used to actuate
dampers in robotics and material handling
applications.
• Other type of limited rotation actuator is a
rack and pinion type actuator.
Speed control
Pneumatic controllers
 Pneumatic controllers Closed loop control system
Closed loop control system.
It mainly includes
• a controller,
• actuator and
• a measuring device
The control can be achieved by using control
electronics or by pneumatic process control.
The pneumatic systems are quite popular
because they are safe.

In the process industries like refinery and chemical plants, the atmosphere is explosive.
Application of electronics based systems may be dangerous in such cases. Since the pneumatic
systems use air, there are very scant chances of any fire hazards. Even though electrical
actuators are available, but most of the valves employed are driven by pneumatic signals.
Components of a pneumatic controller
Components of a
pneumatic controller

Flapper nozzle Feedback

Air relay Bellows Springs
amplifier arrangements
 Flapper nozzle amplifier
One of the basic building blocks of a pneumatic control system is the flapper nozzle
amplifier.
It converts very small displacement signal (in order of microns) to variation of air
pressure.
Air Relay
The major limitation of a flapper
nozzle amplifier is its limited air
handling capacity.
The variation of air pressure obtained
cannot be used for any useful
application, unless the air handling
capacity is increased.
It is used after the flapper nozzle
amplifier to enhance the volume of air
to be handled.
 Types of pneumatic controllers

Types of pneumatic
controllers

Proportional- Proportional- Proportional-

Proportional only
Derivative (PD) Integral (PI) Integral-Derivative
(P) controller
controller controller (PID) controller
Proportional only (P) controller

a pneumatic proportional
controller (viz) components,.
1. flapper nozzle amplifier,
2. air relay,
3. bellows and springs,
4. feedback arrangement.
Proportional-Derivative (PD) controller
To add derivative control action to
a P-only controller, all we need to
place a restrictor valve between the
nozzle tube and the output feedback
bellows, causing the bellows to
delay filling or emptying its air
pressure over time.
Thus, derivative action causes the
output pressure to shift either up or
down (depending on the direction
of input change) more than it would
with just proportional action alone
in response to a ramping input.
Proportional-Integral (PI) controller

In some systems, if the gain is too large the system

may become unstable. In these circumstances the basic
controller can be modified by adding the time integral
of the error to control the operation
Proportional-Integral-Derivative (PID) controller

This is a combination of all the three

controllers described above.
Hence it combines the advantages of all
three.
A derivative control valve is added to
delay the response at feedback bellow.
Addition of derivative term makes the
control system to change the control
output quickly when SP and PV are
changing quickly.
This makes the system more stable.
Advantages & Limitations of pneumatic controllers

Advantages Limitations

Simplicity of the components and no Slow response

complex structure
Easy maintainability Difficult to operate in sub-normal
Safe and can be used in hazardous temperatures
atmospheres
Low cost of installation
Pipe-couplings can give rise to
Good reliability and reproducibility
leaks in certain ambient
Speed of response is relatively slow
conditions
but steady Moving parts - more maintenance
Limited power capacity for large mass
transfer
Actuator control 3/2 valve
 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 2
the spring, the valve is closed 12 10
• In the operated position produced by
the push button the valve is open 3 1

• The push button must be held down

for as long as the cylinder is
outstroked
 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
2
the spring, the valve is closed 12 10
• In the operated position produced by
the push button the valve is open 3 1

• The push button must be held down

for as long as the cylinder is
outstroked
 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
2
the spring, the valve is closed 12 10
• In the operated position produced by
the push button the valve is open 3 1

• The push button must be held down

for as long as the cylinder is
outstroked
 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
2
12 10

3 1
 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 2
be set 12 10

3 1
 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 12
2
10

3 1
 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 12
2
10
for as long as the cylinder is
outstroked
3 1
Actuator control 5/2 valve
 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 4 2
14 12
connected to exhaust port 3. The
cylinder moves plus 5 1 3

• When the button is released port 1

is connected to port 2 and port 4
connected to port 5. Cylinder
minus
 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 4 2
14 12
exhaust port 3. The cylinder moves
plus 5 1 3

• When the button is released port 1 is

connected to port 2 and port 4
connected to port 5. Cylinder minus
 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
4 2
• Full power is developed to drive 14 12
the piston with speed controlled by
5 1 3
restricting the back pressure
 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
4 2
• Full power is developed to drive 14 12

the piston with speed controlled by 5 1 3

restricting the back pressure
 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 4 2

position they were last set 14 12

5 1 3
• The lever valve example illustrated
indicates a detent mechanism. The
lever need not be held once the
new position has been established
 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 4 2
cylinder to instroke or move minus 14 12

• The 5/2 double pilot valve is bi- 5 1 3

stable therefore the push button
valves only need to be pulsed
2 2
12 10 12 10

+ 3 1 - 3 1
 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 4 2
cylinder to instroke or move minus 14 12

• The 5/2 double pilot valve is bi- 5 1 3

stable therefore the push button
valves only need to be pulsed
2 2
12 10 12 10

+ 3 1 - 3 1
 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 4 2
cylinder to instroke or move minus 14 12

• The 5/2 double pilot valve is bi- 5 1 3

stable therefore the push button
valves only need to be pulsed
2 2
12 10 12 10

+ 3 1 - 3 1
 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 4 2
cylinder to instroke or move minus 14 12

• The 5/2 double pilot valve is bi- 5 1 3

stable therefore the push button
valves only need to be pulsed
2 2
12 10 12 10

+ 3 1 - 3 1
 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 4 2
cylinder to instroke or move minus 14 12

• The 5/2 double pilot valve is bi- 5 1 3

stable therefore the push button
valves only need to be pulsed
2 2
12 10 12 10

+ 3 1 - 3 1
 Semi-automatic control
- +
• Manual remote start of a a1

double acting cylinder with A

automatic return
• Cylinder identified as “A”
• Trip valve operated at the 4 2
completion of the plus stroke 14 12
identified as “a1”
5 1 3

2 2
12 10 12 10

+ 3 1 - a1 3 1
 Fully-automatic control
- + a0 a1
• Continuous automatic cycling
A
from roller operated trip valves
• Manual Run and End of the
automatic cycling
4 2 • Cylinder will come to rest in the
14 12
instroked position regardless of
5 1 3 when the valve is put to End
2
10 • Tags for the roller feedback
12
Run/End 3 1 valves a0 and a1 show their
2 2 relative positions
12 10 12 10
a0 3 1 a1 3 1
Sequential control