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 4 : PNEUMATIC CIRCUIT DESIGN (II)

APH - 1 - 4

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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 circuits that were relatively straightforward. In

this lesson we deal with circuits where the sequence of operations is more

complex and, if dealt with in a simple manner, would be inoperative.

There are many methods of designing circuits, some are unique to certain

component manufacturers. Here we will concentrate on the more commonly

used methods.

________________________________________________________________________________________

YOUR AIMS ________________________________________________________________________________________

On completion of this lesson you should be able to:

• identify the location of trapped signals in a two-cylinder circuit

• understand the function of an impulse valve

• use impulse valves to remove trapped signals

• solve sequential control problems for up to three cylinders using the

two group cascade method.

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________________________________________________________________________________________

TRAPPED SIGNALS ________________________________________________________________________________________

In all the circuits we have dealt with so far, the second half of the cycle has

been a repeat of the first half, but with the polarity reversed; this can be

regarded as a 'simple' sequence.

In a 'complex' sequence, the second half of the cycle is not a repeat of the first.

Simple Sequence Complex Sequence

A+ B+ / A– B– A+ B+ / B– A–

Consider the sequence A+ B+ B– A–. This circuit has been designed and

drawn as a simple sequence from the operation and feedback chart shown

below. Follow the operating cycle carefully. In the start up condition both

cylinders are retracted and hence sensing valves a0 and b0 are both operated.

The start valve has been positioned in the line that initiates the first operation

a0 to A1.

Operation

A+

B+

B–

A–

Feedback

Next operation

B+

B–

A–

A+

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FIG. 1

A B

a 0

S T

a 1

b 0

b 1

B 1

B 0

A 1

A 0

a 0

b 0

a 1

b 1

O p

er a

ti o

A +

B +

B –

A –

F ee

d b

a ck

a 1

b 1

b 0

a 0

N ex

t o p er

a ti

o n

B +

B –

A –

A +

T ra

p p ed

si g n a l

T ra

p p ed

si g n a l

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When the start valve is operated a signal passes to A1 but the power valve

cannot move because a signal is already present from sensing valve b0. It is

this signal from b0 which is unwanted at this point, and is known as a trapped

signal.

For the moment, assume that the signal is not trapped and the sequence starts:

cylinder A goes +, operating sensing valve a1. The signal from a1 operates

power valve B1 because the pilot line B0 is exhausted. Cylinder B goes +

operating b1 which sends a signal back to power valve B0; this is where the

second problem occurs. Because cylinder A is still in the + position it means

that sensing valve a1 is still operated causing a signal at B1.

The situation now is that signals are present at B0 and B1 meaning the valve

cannot operate, and therefore the sequence stops.

There are several methods of dealing with these trapped or opposing signals.

Some methods use design procedures that prevent the occurrence of the

signals. Other methods use the simple circuit design techniques, then locate

where the trapped signals would occur and use additional equipment to remove

them.

Produce an operation and feedback chart and draw the circuit for the following

sequence: B– A+ A– B+. Identify the location of any trapped signals that would

cause the circuit to be inoperative.

__________________________________________________________________________________________________

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The operation and feedback chart should be as follows:

The circuit diagram is shown on page 6.

Operation

B–

A+

A–

B+

Feedback

Next operation

A+

A–

B+

B–

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Circuit Diagram B – A+ A– B+ A

a 0

a 1

b 0

b 1

B 1

B 0

A 1

A 0

b 0

a 1

a 0

b 1

T ra

p p ed

si g n a l

T ra

p p ed

si g n a l

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The circuit would be inoperative because of trapped signals between a0 and B1 (preventing the start) and between b0 and A1 preventing cylinder A going.

How can we overcome these problems?

A simple way, without looking at more complex design techniques, is to

remove the signals that would cause the problems immediately after they have

served their purpose.

Because the power valves used are of the bi-stable design, they only require a

pulse of air to be operated. If the pulse is then removed the valve will remain

in position until a signal is presented to the opposite side. Therefore one

solution to the problem is to convert the constant signal which causes the

problem into a short pulse and then exhaust it when it has operated the valve,

leaving the valve ready to be operated from the opposite end. There are two

simple methods of achieving this:

1. one way trip valves

2. impulse valves.

ONE WAY TRIP VALVES

These valves only operate in one direction and are triggered by the action of

the actuating cam. The valve is positioned so that the cam operates the valve

then passes beyond it, this action allows a pulse of air to be sent to the power

valve, and the pulse is then exhausted. On the return action the cam overrides

the valve causing no operation.

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FIG. 2 Operation of One Way Trip Valve

IMPULSE VALVES

Another method of removing trapped signals is to use an impulse valve; this

valve converts a constant signal into a short duration pulse and then exhausts

the pulse after a set period of time. The valve is situated in the signal line

between the sensing valve and the power valve where the trapped signal would

otherwise occur.

FIGURE 3 is the symbol for an impulse valve (sometimes known as an

impulse generator IG).

FIG. 3 Operation of Impulse Valve

Pulse out

Constant signal

Signal out

Valve operated Signal exhausted Valve override

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The valve is similar in operation to a time delay valve except that it is

connected in a normally open manner: when presented with a signal it allows

the signal to pass through. At the same time the air is bled through the flow

restrictor into the reservoir; when sufficient pressure is achieved the DCV

operates against the spring, blocking the incoming signal and exhausting the

downstream signal. When the incoming signal is removed the valve re-sets

itself.

The duration of the pulse is very short, normally less than 1 second.

FIGURE 4 shows the circuit A+ B+ B– A– modified using impulse valves

to remove the trapped signals.

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FIG. 4 Use of Impulse Valves

A B

a 0

S T

a 1

b 0

b 1

B 1

B 0

A 1

A 0

a 0

b 0

a 1

b 1

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Draw the complete circuit with impulse valves inserted for the sequence B– A+ A–

B+ as used in question 1 on pages 5 and 6.

__________________________________________________________________________________________________

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The circuit diagram for B– A+ A– B+ with impulse valves is shown below. A

a 0

a 1

b 0

b 1

B 1

B 0

A 1

A 0

b 0

a 1

a 0

b 1S T

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Care must be taken with the use of impulse valves because spurious pulses can

occur when the air supply is first turned on to the circuit. These pulses only

occur under certain conditions and they can be "designed out".

Impulse valves can be used to solve most problems associated with trapped

signals; however, in complex circuits with many cylinders it is difficult to spot

where the trapped signals will occur and so it is difficult to place the impulse

valves correctly.

THE CASCADE SYSTEM

This is a system of circuit design which ensures that trapped signals never

occur. It has been used successfully in industry for many years.

There are several different cascade methods in use. Each one has its

advantages and disadvantages, but each one uses the principle that the air

supply to critical sensing valves is switched on and off in groups. This ensures

that a power valve cannot receive two signals at once.

The cascade method we describe here is still one of the most commonly used.

The cascade technique is to switch on and off the supply air to the critical

sensing valves in groups. The need for this will occur when a sensing valve

mechanism is still held down, but the output signal has been used and needs

removing. By arranging the sensing valves in groups it is possible to switch

off the air supply to a particular group when required and hence eliminate the

trapped signals. This switching is achieved by the use of one or more group

selection valves. The air supply is switched back on to the relevant sensing

valves in time for their next operation.

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Method

1. Label each cylinder with a capital letter and write down the sequence of

desired operation.

A+ B+ C+ B– D+ D– A– E+ E– C–

2. To determine the number of cascade groups for any sequence, the

sequence must be split into groups. This should be done so that no letter,

regardless of its sign (+ or –), appears more than once in any group. To

ensure that the sequence breaks up into as few groups as possible try

splitting both from the front and the back. Each group is labelled with a

roman numeral.

Splitting from the front:

A+ B+ C+ / B– D+ / D– A– E+ / E– C– (four groups)

I II III IV

Splitting from the rear:

A+ B+ / C+ B– D+ / D– A– E+ / E– C– (three groups)

I II III I the last two letters

join the first two as

group I.

Splitting from the rear here provides the better solution as there is one less

group.

The cascade sub circuit will require as many five-port valves as there are

groups, with the exception of the two group system which only requires

one changeover valve.

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Split the following sequence into groups and state how many group changeover valves

will be required for a cascade system.

A+ B+ B– A–

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

__________________________________________________________________________________________________

The sequence would be split as follows:

A+ B+ / B– A–

I II

There are two groups so one 5/2 changeover valve will be required.

The changeover valve would be labelled and the outputs would be connected to a bus bar

system as shown in FIGURE 5.

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FIG. 5 Group Changeover Valve (Two Groups)

Connections

The following rules will allow all the circuit connections to be made.

1. The last sensing valve to be operated in any group will select the next

group and will be supplied with mains air.

2. All other sensing valves will be supplied with air from their respective

group output line.

3. All power valves will have their inlets supplied with mains air.

4. The start valve will be placed in the line that selects group I. In

circumstances where the first operation in the sequence falls in the middle

of the group, the stop/start valve would be placed in the pilot line that

initiates that operation.

5. All other connections are made in the normal way i.e. the signal obtained

from the completion of one operation initiates the next.

GP II output

GP I output

I II

Select GP I Select GP II

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Let us consider the sequence A+ B+ B– A– and work through the rules to

obtain the connection details.

The group splits: A+ B+ / B– A–

I II

b1 mains air and select gp II

a0 mains air and select gp I

a1 from gp. 1

b0 from gp. II

3. Complete the sequence using the operation and feedback chart.

FIGURE 6 is the completed circuit for the sequence A+ B+ B– A–.

1. Decide which sensing valves are to

be supplied with mains air and

select the next group (last in each

group).

2. Decide which trip valves are to be

supplied with air from the group

outputs.

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FIG. 6 Two Group Cascade A+ B+ B– A–

A B

a 0

S T

a 1

b 0

b 1

B 1

B 0

A 1

A 0

a 0

b 0

a 1

b 1

G P

I I

o u tp

u t

G P

I o

u tp

u t

S el

ec t

G P

I S el

ec t

G P

I I

I II

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OPERATION

On start-up the cylinders are sitting on sensing valves a0 and b0. a0 is the last

sensing valve operated in gp II, therefore it receives mains air and selects gp I

via the stop start valve.

When the start valve is operated gp I is selected; the output is used to operate

A1 power valve and supply a1 sensing valve.

Cylinder A goes + and operates a1 sensor which signals B1 power valve. The

other end of the power valve B0 is exhausted via the gp select valve. Cylinder

B goes + and operates b1 sensor which is supplied with mains air; b1 selects gp

II. The selection of gp II exhausts gp I output line and hence removes what

would have been a trapped signal from B1. Group II output line is now

supplied with air; this is used to operate B0 and supply b0 sensing valve.

Cylinder B goes –, and operates sensor b0 which operates A–. Cylinder A goes

–, a0 selects gp I and the cycle is complete.

Using the cascade method, produce a circuit diagram to fulfil the following sequence of

operations: A+ B– B+ A–.

__________________________________________________________________________________________________

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The circuit diagram should be as follows. A

a 0

S T

a 1

b 0

b 1

B 1

B 0

A 1

A 0

a 0

b 1

b 0

G P

I I

G P

S el

ec t

G P

I S el

ec t

G P

I I

I II

a 1

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CASCADES FOR THREE GROUPS

Finally, whilst we will not pursue yet more complex designs, included in

FIGURE 7 is a group cascade valve arrangement using three valves for a three

group cascade.

FIG. 7

Group I

Group II

Group III

Start

Stop

Select I

Select II

Select III

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ELECTRO-PNEUMATICS

We can see from FIGURE 7 that more complex sequencing requires complex

pneumatic circuits. An alternative method of controlling the sequence of

cylinder movement is to use an electronic programmable sequence controller

or programmable logic controller (PLC). Electronic sequencing devices can be

used to provide signals for a sequence of events (cylinder actuations).

They are particularly appropriate where the sequence is complex and would

therefore require a large number of groups in a cascade system, or where there

may be a requirement to vary the sequence for a given cylinder arrangement.

Electronic controllers consist of a programmable chip with inputs and outputs.

The inputs to the chip come from electrical sensing devices (e.g. reed switches)

which detect the position of the actuator (replacing the position-sensing valves

seen previously in the lesson). The output signals from the chip are fed to the

control valve.

As the controller outputs electrical signals, then the controlling valve which

receives this signal must be electrically operated. This can be achieved with

the use of solenoid activated control valves.

FIGURE 8 shows a typical arrangement of an electro-programmable controller.

There are several advantages to this arrangement over a purely pneumatic

circuit: it is not necessary to design and build the complex cascade systems

necessary in purely pneumatic systems; it is possible to change the sequence of

operations without altering the connections between the cylinders and control

valves; electronic controllers can easily be used to facilitate counting

operations.

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FIG. 8 Electro-Pneumatic Circuit Diagram

A Ba0 b0

a1 b1

Electronic controller

Outputs

Inputs

1 2 3 4 5 6 7 8

a1 b0 b1

Solenoid operated control valves

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EMERGENCY STOP

An emergency stop or shutdown is vital in circuits where there is a risk of

injury or damage. There are many options, here we will look at one example

of an emergency stop.

FIGURES 9(a) and 9(b) show the operation of the emergency button. Pressing

the emergency stop button:

(i) traps the pilot signal (1)

(ii) provides a signal (2) to the left-hand side of the 5/2-way valve

(iii) operates the valve 'A' trapping the pilot signal (3) and allowing the right-

hand side of the 5/2-way valve to exhaust.

Therefore, when the emergency stop button is pressed, the 5/2-way valve

causes the cylinder to park in the retracted position.

The operation of the resent button causes the emergency stop valve to be

returned to the normal working position.

An emergecny situation may occur when there is a lack of air supply to a

circuit, therefore it is necessary that there is a separate air supply for the

emergency circuit, provided from a reservoir or accumulator.

Note that the emergency stop and failsafe circuits use a different configuration

of 5/2 valve. This is not necessary for the operation of an emergency stop or

failsafe circuit, they are used here to introduce alternative valves.

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FIG. 9(a) Emergency Stop Circuit in Normal Operation

Emergency air supply

Cylinder movement

Pilot

Emergency stop

Pilot (1)

Reset

Emergency air supply

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FIG. 9(b) Emergency Stop Circuit in Emergency Stop Position

FAIL SAFE

If pneumatic and hydraulic circuits present a potential danger it is important to

ensure that they will react in a safe manner if there is a failure in the supply of

the working fluid. Circuits can be designed to a 'fail safe' condition, which

ensures that they fail to their least hazardous condition.

As the fail safe is to operate in the case of a failure in supply of fluid, it is

important that a separate protected supply is provided.

In the pneumatic crcuit shown in FIGURE 10(a), the air supplying the

cylinders via the 5/2 control valve is also fed to the spring-operated pressure-

sensitive valve. This pressure switch is set so that if the pressure of the air

Emergency air supply

Retracted cylinder in (parked) position

Pilot (3)

Emergency stop

Pilot (1)

Reset

Emergency air supply

(2)

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falls below a pre-set value, the valve will be operated (FIGURE 10(b)) and air

from the reservoir will be directed to the 3/2 valves, opeating these and causing

the cylinder to retract to safe parking position. Note that it is the air from the

'protected supply' which is used to drive the cylinder.

FIG. 10(a) Double Acting Cylinder Control in 'Normal Running' Condition

Mains air

Non-return valve

Reservoir

Reset

Pilot (normal

operation)

Pilot (normal

operation)

Manually set pressure switch

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FIG. 10(b) Double Acting Cylinder Control in 'Failed' Condition

Mains air

Non-return valve

Reservoir

Reset

Pilot (normal

operation)

Pilot (normal

operation)

Manually set pressure switch

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________________________________________________________________________________________

NOTES ________________________________________________________________________________________

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

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________________________________________________________________________________________

SELF-ASSESSMENT QUESTIONS ________________________________________________________________________________________

1. Draw the symbol for an impulse valve.

2. Using the cascade method produce a circuit to operate three cylinders in

the following sequence: A+ B+ B– C+ A– C–.

3. Using impulse valves to remove trapped signals produce a circuit to

operate two cylinders in the following sequence: B+ B– A– A+.

4. State the minimum number of groups the following sequence will split

into: A+ A– B– B+ C– D+ D– C+.

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________________________________________________________________________________________

NOTES ________________________________________________________________________________________

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

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________________________________________________________________________________________

ANSWERS TO SELF-ASSESSMENT QUESTIONS ________________________________________________________________________________________

1. Symbol for impulse valve.

2. The sequence splits as follows A+ B+ / B– C+ A– / C–

I II I

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Circuit Diagram A+ B+ / B– C+ A– / C– A

a 0

S T

a 1

A 1

A 0

c 0

G P

S el

ec t

G P

I S el

ec t

G P

I I

b 1

a 1

a 0

c 1

c 0

c 1

C 1

C 0

b 0

b 1

B 1

B 0

G P

I I

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3. Circuit diagram using impulse valves: B+ B– A– A+. A

a 0

a 1

b 0

b 1

B 1

B 0

A 1

A 0

b 0

b 1

a 0

a 1

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4. The minimum number of groups is three:

A+ / A– B– / B+ C– D+ / D– C+

I II III I

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________________________________________________________________________________________

SUMMARY ________________________________________________________________________________________

Circuits which are not of a simple repeating sequence can have problems

associated with trapped signals, causing them to be inoperative.

These trapped signals can be removed using impulse valves placed between

the sensing valve and power valve. With circuits using several cylinders

identifying the location of the trapped signals can be difficult.

The cascade method of circuit design eliminates any problems of trapped

signals; the design method can be tricky at first but once mastered it can be

used to solve many sequential control problems.

It is important with cascade circuit design that the rules are learnt and

followed. The more circuits that are drawn using this method the easier it

becomes.

The operation and feedback chart is a useful tool for identifying the

connections between sensing valves and power valves and should be produced

for each circuit attempted.

Electronic programmable controllers are commonly used in pneumatics and

can eliminate the need for complex pneumatic circuits.

Emergency stop and fail safe circuits are used to provide protection against

damage and injury.

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