Fluid Power Diagrams and Questions (Mechanical engineering Pneumatic & hydraulic)

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MODULE TITLE : APPLICATIONS OF PNEUMATICS AND

HYDRAULICS

TOPIC TITLE : FLUID POWER DIAGRAMS

LESSON 3 : PNEUMATIC CIRCUIT DESIGN (I)

APH - 1 - 3

Published by Teesside University Open Learning (Engineering)

School of Science & Engineering

Teesside University

Tees Valley, UK

TS1 3BA

+44 (0)1642 342740

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________________________________________________________________________________________

INTRODUCTION ________________________________________________________________________________________

In the last lesson we dealt with the graphical symbols used to represent fluid

power circuits. Here we show how these symbols are built up to form

complete circuits.

The circuits initially are simple single-cylinder systems, used to illustrate

methods of obtaining control of speed, constant reciprocation and also delays

between operations. We go on to introduce the concept of sequential control of

multi-cylinder systems and look at different methods of circuit presentation.

The emphasis throughout this lesson is placed on the design and drawing of

circuits to satisfy a given criteria.

________________________________________________________________________________________

YOUR AIMS ________________________________________________________________________________________

On completion of this lesson you should be able to:

• understand the advantages to be gained by indirect operation of

actuators

• design a circuit to produce the correct method of speed control of a

pneumatic actuator

• design a circuit to introduce a time delay between operations

• design circuits that will give sequential control of multi-cylinder

systems using operation and feedback charts

• be able to produce circuit diagrams using the preferred method of

circuit presentation.

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________________________________________________________________________________________

CONTROL OF ACTUATOR MOTION ________________________________________________________________________________________

There are four important aspects to consider regarding the control of

pneumatic actuators:

• direction of motion (directional control valves)

• force output (pressure control valves)

• actuator velocity (flow control valves)

• sequence of operation (circuit design)

We have dealt briefly with the first three in previous lessons and further work

is included within this lesson; the fourth will be introduced at a basic level.

CIRCUIT PRESENTATION

No international standard for the layout or labelling of circuits exists at the

time of writing, and so we will illustrate the two most commonly used systems.

The first entails drawing the circuit with position-sensing valves in their

physical positions. The second uses a system of labelling the position of

sensing valves and positioning them away from their physical location; this has

the effect of reducing the number of crossed lines on more complex circuits,

making them easier to read.

POWER AND CONTROL VALVES

Directional control valves can be classified as either "power" or "control"

valves. Power valves are used to supply air which is used to directly move an

actuator and should be sited as close as possible to the actuator being powered.

Control valves are used for signal processing operations, normally to operate a

power valve or to detect position.

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FIGURES 1 and 2 illustrate a single-acting spring return cylinder being

operated directly and indirectly.

FIG. 1 Direct Operation

FIG. 2 Indirect Operation

Explain the major advantage circuit 2 has over circuit 1.

....................................................................................................................................................

________________________________________________________________________________________

3 1

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With circuit 2 the power valve can be situated close to the cylinder while the

control valve can be situated some distance away. With the power valve

situated close to the cylinder, pressure drop will be minimal and control of

motion will not be affected by large volumes of compressible air in the pipes.

The control valve is required to supply only relatively low pressures and

volumes to operate the power valve; therefore small control valves and small

bore piping can be used.

FIGURES 1 and 2 showed the operation of cylinders returned by springs.

Consider a double-acting cylinder which must be powered in both directions in

a semi-automatic mode. The outstroke of the cylinder must be initiated

manually and it must return automatically.

FIGURE 3 illustrates a circuit which achieves this operation. The power valve

in this case is a bi-stable valve (it has no springs and therefore retains

whichever position was last assumed until another signal is received).

FIG. 3 Semi-automatic Operation of a Double-Acting Cylinder

Start valve (ST)

Sensing valve

Bi-stable valve

A+ A–

A –

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The cylinder is labelled using capital letters (A), its position being either

forward (+) or retract (–). Position-sensing valves are labelled using binary

notation and lower case letters, retract = 0, forward = 1. The power

valve has its actuating devices labelled with the function they initiate A+ or

A–. The control valve which initiates operation is the start valve (ST).

The start valve is depressed then released: this supplies a pulse of air to the

power valve, changing its position and powering the cylinder out (A+). When

the cylinder is fully outstroked it actuates position-sensing valve a1 which

sends a pulse of air to the opposite end of the power valve (A–) causing the

cylinder to retract and stop ready for the next operation of the start valve.

Produce a circuit diagram and label it using the method shown above to effect the

following operation. A double-acting cylinder must be powered in both directions and

must be capable of fully automatic cycling (constant reciprocation). It must be

possible to start or stop the cycle using one stop start valve.

________________________________________________________________________________________

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Your circuit diagram should look as follows:

Operation – to achieve continuous operation it is necessary to use two

position-sensing valves a0 and a1; these detect that the command movement

has been completed and cause the next operation to occur. To allow stop and

start of the cycle a 3/2 double lever operated DCV is included in the control

line that causes the first operation (a0 to A+). It should be noted that in the "at

rest" condition A– the sensing valve a0 is in the operated condition: therefore

the connections are drawn to the upper box. When the start valve is operated

the power valve receives a signal at A+ and thus changes position causing

cylinder movement A+. At the same time the A– end of the power valve is

exhausted to atmosphere. Proof that the cylinder has achieved its A+ condition

is given by the operation of sensing valve a1 which signals the power valve A–;

this causes the cylinder to retract. Proof of the retract condition is given by

operation of a0 which supplies a signal to the stop start valve; if the valve is in

the stop condition the cycle ends, if it is in the start condition the cycle repeats.

1 2

A –

A+ A–

Start Stop

a03

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________________________________________________________________________________________

SPEED CONTROL ________________________________________________________________________________________

Control of actuator speed is carried out by regulating the flow of air either into

(meter in) or out of (meter out) the actuator.

Meter In

This method of speed control entails limiting the rate that air enters the

actuator using a flow restrictor; in fact, it is rarely used because it poses several

problems:

(i) the air can have a high pressure drop passing through the flow restrictor

which limits the amount of force the actuator can produce

(ii) it can only be used when the load constantly opposes motion.

This kind of speed control should only be used for single acting actuators, or

where the actuator being controlled has insufficient volume on the exhausting

side to provide an air cushion (i.e. small diameter or short stroke cylinders).

Meter Out

This method is generally accepted as being the best method of controlling

actuator speed. The flow control valve is situated to control the flow of the

exhausting air and hence impose a back-pressure opposing motion ; this back-

pressure achieves good control of actuator speed but results in a reduction of

force out of the actuator. This method has the added advantage that suspended

loads can have their speed controlled.

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FIG. 4

Meter Out in both Directions

If the speed of an actuator is to be controlled using the meter out method in

both directions, it is necessary to use restrictor valves with an integral check:

this allows unrestricted flow of air into the cylinder while restricting the flow

out. It is desirable that any speed control restrictor is sited as close as possible

to the actuator being controlled; this reduces the volume of compressible fluid

between the actuator and the valve which gives better control. FIGURE 5

illustrates the principle.

FIG. 5 Meter Out Speed Control in both Directions

Free flow

Metered flow

METER IN Poor control, use only when

meter out is impossible.

METER OUT The best method, can control

suspended loads.

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Exhaust Port Restrictors

A method which is popular due to its cost effectiveness and ease of installation

is the meter out method using exhaust port restrictors. These are small

variable flow control valves that screw directly into the threaded exhaust ports

of the power valve as shown in FIGURE 6.

FIG. 6 Meter Out using Exhaust Port Restrictors

While these restrictors do have cost advantages they do have certain

disadvantages that should be considered before they are selected.

(i) They cannot be sited as close to the actuator as conventional restrictors,

therefore speed control is not as precise.

(ii) If they are used to control the speed of cylinders with large diameter

piston rods, pressure between the restrictor and the actuator may intensify

and cause damage to seals within the power valve.

Consider the following arrangement:

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FIG. 7

Force (F) is equal on both sides of the piston therefore

Care must therefore be taken with the selection, setting and positioning of flow

restrictors when using large diameter piston rods.

p A F p A

p A p A

p p A

1 1 2 2

2 1 1

× = = ×

∴ × = ×

∴ = ×

2 6 0 01

0 003 Inserting the values

. .

= ×

22 20= bar

pressure = force area

p F

F p A∴ ×

A2 = 0.003 m 2

A1 = 0.01 m 2

p1 = 6 bar F

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________________________________________________________________________________________

TIME DELAYS ________________________________________________________________________________________

There is often a need to set up a time delay between one operation and the

next. This delay may be anything from a few seconds to several minutes.

Most pneumatic equipment manufacturers supply time delay valves that

operate in similar ways. The valve is normally closed: when it is presented

with a signal it starts the timing process; after some pre-determined period the

valve opens and allows the signal through. These valves normally consist of

three components included in one unit:

a 3/2 pilot operated spring return DCV

a variable restrictor with integral check

a reservoir.

FIG. 8 Time Delay Valve

Operation – the signal passes through the pilot line to the flow restrictor where

it is bled through to the reservoir. When sufficient pressure has built up within

the reservoir to overcome the spring pressure the valve is opened allowing a

flow from 1 to 2 and onto the signal destination. When the signal is removed

the valve re-sets itself. The duration of delay is a function of the reservoir size

and the setting of the flow restrictor.

Signal source

Signal destination

12 1

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The valve is normally situated between the position-sensing valve and the

power valve which must have its operation delayed.

A double acting pneumatic cylinder is to be used to clamp a component and hold it for

10 seconds while another operation is carried out. The cylinder must have meter out

speed control in both directions and must be capable of being operated continuously or

as a single cycle.

Produce a circuit diagram that will achieve this and explain its operation. (Sequence

of operation = A+ 10 sec delay A– repeat)

....................................................................................................................................................

________________________________________________________________________________________

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Your circuit diagram should be as shown.

Operation - when the start valve is operated the power valve is moved to the

A+ position causing the cylinder to outstroke and clamp the component; speed

control is by restricting the exhausting air. Sensing valve a1 sends a signal to

the time delay. The restrictor is set so that it takes 10 seconds for sufficient

pressure to build up in the reservoir to open the delay valve. When the time

delay opens the signal operates the power valve A– causing the cylinder to

retract. Sensing valve a0 sends a signal to the stop start valve: if the valve is

closed the cycle stops, if the valve is open the cycle continues.

A+ A–

3 12

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________________________________________________________________________________________

SEQUENTIAL CONTROL OF TWO OR MORE CYLINDERS ________________________________________________________________________________________

Up until now we have only dealt with the control of single actuator circuits.

Many machine operations require the use of several cylinders operating in a

given sequence. To aid the design of such circuits it is useful to produce an

operation and feedback chart.

With this chart the cylinder operations are plotted vertically in the first column,

the feedback operations vertically in the second (sensing valve), and the next

operation that is caused by the operation of the sensing or feedback valve is

plotted in the third column. FIGURE 9 shows a typical chart for two cylinders

that operate in the sequence A+ B+ A– B–.

FIG. 9

The chart is read horizontally one line at a time. Consider line 1 (A+).

Cylinder A goes + which activates sensing valve a1 which gives a signal to

power valve B+ which causes cylinder B to go +, which leads us onto the

second line, and so on.

The advantage of this chart is that we can see at a glance which sensing valves

are connected to the relevant power valves.

Cylinder operation

A+

B+

A–

B–

Feedback operation

Next cylinder operation

B+

A–

B–

A+

actuates actuates

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Produce an operation and feedback chart for three cylinders to work in the sequence

A+ C+ B+ A– C– B–.

________________________________________________________________________________________

Operation Feedback Next operation

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Going back to our two cylinder sequence, A+ B+ A– B–, the circuit can be

drawn and the connections determined from the chart. The first step is to draw

the cylinders and all the relevant valves, a 5/2 power valve for each cylinder

and a 3/2 sensing valve at each extreme of cylinder movement. The valves and

cylinders are then labelled. All main air supplies are then connected to the

power valve and the sensing valves. Sensing valves that are operated in the "at

rest" condition have the mains air connections shown to the upper box.

Cylinders are all drawn in the start up condition which may be either + or –.

The power valves now have their cylinder connections drawn in.

The only thing that remains is to draw in the sensing valve to power valve

connections: these connections are determined by referring to the operation

and feedback chart.

The circuit in FIGURE 10 shows the sequence A+ B+ A– B– with all the

connections made.

Operation

A+

C+

B+

A–

C–

B–

Feedback

Next operation

C+

B+

A–

C–

B–

A+

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FIG. 10

A +

A –

a 0

S T

a 1

b 0

b 1

B +

B –

–

+ A

–

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Produce a circuit diagram for the operation and feedback chart you made for the

sequence A+ C+ B+ A– C– B–.

________________________________________________________________________________________

Operation

A+

C+

B+

A–

C–

B–

Feedback

Next operation

C+

B+

A–

C–

B–

A+

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Your circuit diagram should be as follows.

A +

A –

a 0

S T

a 1

b 0

b 1

B +

B –

c 0 c 1

C +

C –

B C

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This method of designing circuits works perfectly well for what are termed

simple sequences, that is where the second half of the cycle is a repeat of the

first, only the direction of motion is reversed. But the method would cause

problems for a cycle where the second half order was different i.e. A+ B+ B–

A–. This kind of circuit will be discussed in the next lesson.

PREFERRED METHOD OF CIRCUIT LAYOUT

We mentioned earlier that no standard for circuit layout exists at the moment

and many different circuit arrays will be encountered. However, many

designers are adopting a method of circuit presentation that reduces the

number of crossed lines on the circuit drawing, thereby making the reading of

the drawing much simpler.

This method involves placing the sensing valves underneath the power valve

actuator that they operate, instead of at the piston stroke extremes. Any valve

that is mechanically operated in the start up condition has a cam drawn

adjacent to the valve actuator, and the connections are made to the operated

box.

All valves are drawn in the horizontal position and a bus bar connection

system is used wherever possible (this will be illustrated in the next circuit).

All sensing valves are labelled and the position that they are operated from is

marked and labelled.

The power valves also adopt the binary identification code – for example, A0,

A1.

FIGURE 11 shows the preferred method of circuit presentation for the

sequence A+ B+ A– B–.

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FIG. 11

A B

a 0

S T

B 1

B 0

A 1

A 0

b 0

b 1

a 1

a 0

b 0

b 1

B u s

b a r

a 1

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That concludes this lesson on basic circuits: now attempt the Self-Assessment

Questions that follow.

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________________________________________________________________________________________

SELF-ASSESSMENT QUESTIONS ________________________________________________________________________________________

1. Give two reasons why meter out speed control is preferred to meter in.

2. Draw the symbol for a pneumatic time delay valve.

3. Produce an operation and feedback chart for the sequence A+ B– C+ A–

B+ C–.

4. Produce a circuit diagram using the preferred method of presentation for

the sequence given in question 3.

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________________________________________________________________________________________

ANSWERS TO SELF-ASSESSMENT QUESTIONS ________________________________________________________________________________________

1. Meter out speed control is preferred for the following two reasons:

(i) it can be used for the control of suspended loads

(ii) it allows full pressure to act on the surface of the actuator in the

direction of motion and so the only force reduction is due to the back

pressure of the exhausting air.

2. The symbol for a pneumatic time delay valve is:

3. Your chart should be as follows:

Operation

A+

B–

C+

A–

B+

C–

Feedback

Next operation

B–

C+

A–

B+

C–

A+

3 1

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4. Preferred Circuit Presentation.

a 0

S T

A 1

A 0

c 0 c 1

b 0

B 1

B 0

a 0

a 1

b 1

c 0

C 1

C 0

b 0

c 1

b 1

a 1

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________________________________________________________________________________________

SUMMARY ________________________________________________________________________________________

In this lesson we have dealt with methods of controlling the speed and

sequence of operation of pneumatic actuators. We have seen that the best

method of controlling speed is by the meter out method.

When multiple cylinders are to be operated in a given sequence an operation

and feedback chart is recommended to aid the sequence design.

Wherever possible, use the preferred method of circuit presentation as this

simplifies the circuit layout.

Time delay valves are inserted between the sensing valve and the power valve

that they control.

The stop start valve is inserted in the line which effects the first operation of

the sequence.

Circuit designing requires practice: the greater the number of circuits

attempted, the more familiar you will become with the symbols and the

principles involved.

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setdistillerparams << /HWResolution [2400 2400] /PageSize [612.000 792.000] >> setpagedevice