UNIT-IV

PNEUMATIC SYSTEMS
Back Pressure Sensor
• The back pressure sensors consist of a small nozzle exhausting air to the
atmosphere. When the nozzle is blocked, the pressure backs up and this increased
back pressure signals the presence of an object.
• A restriction must be placed between the supply pressure inlet and the nozzle.
This restriction could be short length capillary tubing or a small hole drilled into a
plug inserted in the tube. Its purpose is to produce sufficient pressure drop so as to
get a low output pressure when the nozzle is open. The reason for this is that the
sensitivity of sensing will be better if the pressure is low.
• If the sensed object blocks the nozzle outlet, the restriction has no effect, and
output pressure P almost equals supply pressure P. Therefore the object can be
sensed only if it practically touches the nozzle.

Proximity Sensor
• A proximity sensor permits the detection of objects at greater distances (can be as
large as 20 mm) than what is possible with back pressure sensors. The conical jet
proximity sensor uses an annular nozzle, surrounding a sensing hole, connected to
the output port.
• The sensor supply pressure is let into the annular space, so that a conical jet forms
at the nozzle, enclosing a low pressure bubble within the flow cone. Hence, the
output pressure P at the sensor opening into the base of the cone is normally
slightly below the atmospheric pressure. When an object comes near the flow
cone, a portion of the supply jet is reflected from the object back into the low
pressure bubble region. This increases the output pressure P to permit the
switching of an appropriate switching element.
 • The drawbacks of this sensor are relatively high air consumption and relatively
high cost as compared to the back pressure sensors. Also, the output pressure P
that can be obtained is very low, so the signal must generally be amplified.
Gap Sensor or Interruptible Jet Sensor
• Interruptible jet sensor consists of a nozzle and a receiver tube. The nozzle
transmits air pressure P across a gap to the receiver, thus producing a small output
pressure P. If an object is placed between the nozzle and the receiver, the jet is
interrupted and P drops to zero.
• The switching elements receiving the output signal may reverse it.

• Interruptible jet sensors are simple and relatively inexpensive. The drawbacks that
only relavobuitt us with proximity sensors, the output pressure obtainable is very
low, so amplification is generally needed.
Limit Switch
• Limit switch senses the object by physical contact. When an object comes in
contact with the actuator the output switches from 02 to 01. When the contacting
object is removed, the output switches back.
Pressure Sensors
• Pressure sensing is achieved with piston type pressure sequence valves. When a
pre set pressure level is reached, the pressure sequence valve provides a signal.
This gnal in turn can be used for further switching combination. Symbols for
Pressure Sequence Valve
Switching Elements
• Switching elements in the for of logic gates like OR, NOR are being used along
with per pneumatic circuit to offer better control to the pneumatic system. The
different of pneumatic switching elements are
1. Pneumatic valves
2. Pneumatic moving-part logic
3. Fluidic element
Pneumatic Valves
 • All pneumatic direction control valves possess logic characteristics. To obtain
logic functions, the valves can be combined appropriately. For example 312
direction control valves can be used to provide an AND function as in figure 13.7
(a). Here 2 numbers of 3-way 2 position air pilot spring return valves have been
used. There are 3 incoming tubes A, B and C. All the three lines must be
pressurized get an output signal 1.

In a NOT function, the output is ‘ON’ only when all control signals are ‘OFF and vice
versa. As in figure 13.7(a), the function consists of three two way two position at pilot
spring return valves connected such that the output will not exist if any one control signal
is not received.
• The two pneumatic logic gates, i.e. the shuttle valve and the twin pressure valve,
are also adopted to provide logic functions. For example, the figure 13.8
illustrates OR function with a shuttle valve.
• Here two numbers of shuttle valve are used. There are three incoming pulses A,
B, C. If any pulse A or B or C is present, an output signal will be present at T.

Moving-Pan Logic Elements

• As pneumatic control switch became more complex, it realized that Should be as
small as possible to reduce cost and mounting space. So special minimum
pneumatic elements were developed to implement the various logic gates.
• Since these elements use moving parts, such as diaphragms, springs, disks, balls
and poppets they are referred to as moving-part logic (MPL) elements. They are
smaller than the direction-control valves and typically cost half as much. AND
MPL element The Fig. 13.9 shows an AND MPL element. It has two inputs ‘a’
and ‘b’ and one output ‘5’.
 • The AND element delivers an output ‘5’ only if both inputs are pressurised
simultaneously. If input ‘a’ appears alone, poppet seats to the right preventing
output. If input ‘b’ appears alone, poppet seats to the left, preventing output.

OR MPL element The OR MPL element is a shuttle valve using a poppet disk
instead of a ball.
• The OR element delivers an output ‘5’ if ’a’ or ‘I or both are present. Input ‘a’
alone seats poppet on the right hand seat and appears as output S. Input ‘b’ alone
seats poppet on the left hand seat and appears as output ‘5’.

NOT MPL element The NOT MPL element is shown in the Fig. 13.11. It has a
supply pressure ‘P’. If input ‘a’ is not present, supply pressure P reaches output S. If
input pressure ‘a’ is present, supply pressure P is blocked and S is exhausted to the
atmosphere.
• These M elements are connected using thin plastic tubing. Alternatively, small
‘integrated circuits’ can be constructed using special connecting plates in which
holes are cut and the partitions removed to create the necessary air passages.
Since.can be done by the user, compact circuits can be built at low cost.
Fluidic Element
• The early sixties, a new type of pneumatic control elements called fluidic
elements or fluid logic elements was developed. The biggest advantage of these
elements overall other forms of control elements is that they have a minimum
number of mechanical moving parts. Because of this, these elements are also
known as ‘non-moving logic controllers.
The various advantages of fluidic elements are:
i No wear and tear of elements.
ii. No actuating force needed.
iii.Very little space needed for mounting.
iv. Quite insensitive to temperature, vibration, shock, electric noise and radiation.
The entire development of fluidic technology is based on the wall attachment
phenomenon, which was first discovered by the Rumanian engineer Henri Coanda I
1932, this phenomenon is frequently called ‘Coanda effect’.

• A free jet of air is emitted into a confined region or orifice at a velocity’ enough
to produce turbulent flow. The free jet of air will continue in a given pulling in
with it the available air from its surroundings as it leaves the orifice.
• If there is greater availability of this entraining air from one side, a small vortex
(low pressure area) is created near the nozzle exit. This low pressure area then
tends to attract the free jet, distorting it and pulling it towards the wall, because
the atmospheric pressure on the other side forces the jet to cling to the surface.
• This free jet attachment continues until a small air supply is fed to the low
pressure area, thus relieving the attraction of the jet to the wall. ‘When this signal
is injected, the free jet then detaches itself from the wall and resumes its normal
uninterrupted flow path.
The various fluidic elements are briefly explained here.
Ri-stable flip flop in this, the air flow is going from the input P down through the 01
channel or the 02 channel depending upon the signal from either C or

Cr
• A truth table tells how a particular device behaves. Number 0 means ‘OFF’ and
number I mean ‘ON’ for all devices. Therefore when control signal C is ‘ON’ and
control signal C is ‘OFF’ the output is at 01. If C is then turned ‘OFF’ the device
stays its first stable and the output is at 01. If C2 is ‘ON’ and control signal Cl is
‘OFF’ the output is at 02. Removing signal C leaves the device in its second
stable with the output at 02. Thus the flip-flop has two stable states when control
signals are ‘OFF’.
• Initially the basic flip-flop has its power supply pressure P turned ‘ON’ and
neither control signal has been turned ‘ON’. Otherwise, both the control signals C
C should be ‘ON’ simultaneously. Under these conditions, the output flow would
split because no low pressure bubble can be sustained on either wall.
C ‘ON’, the flip-flop does not produce any useful signal.
OR/NOR gate device. This element has outputs corresponding with two
conditions:
OR — pressure at one or any combinations of the control port
NOR— pressure at none of the control ports
• The OR/NOR gate is designed in such a manner that flow will always be in
NOR signal when no control signal is present; of course P is present. The 02 port
represents the NOR output and the 01 port represents the OR output.
• Either a C or C signal must be present to get an output at the C, port. But neither
or C should be present to get an output at the 02 port. AND/NA ND gate Another
element is the AND/NAND gate, which is similar to NOR gate, except that the
NOR gate is used to determine when none of the control signals is present,
whereas the AND gate is used to determine when all the control signals are
present.

• Both the C and C control signals are present to get an output at the 01 port. The
absence of either or both signals will result in the stable output at the 02 port.
Diaphragm amplifier
 • The output pressure of fluidic elements is extremely low. Since this is insufficient
to pilot lines of a normal cylinder actuating valves, special diaphragm amplifiers
must be used to boost each output signal.

• The diaphragm amplifier uses a large diaphragm as a control spool. The pressure
port (P) is connected to the normal main line pressure.
• A pilot port (Y) acts as the control pressure port to the valve and through this
orifice the control jet is allowed inside the amplifier on the other side of the
diaphragm.
• This causes the diaphragm to shift and P opens to output port (A), vent (R)
remaining closed. So the pres of a normal pneumatic line passes through A and
continues further downstream.
• If control jet is in the ‘OFF’ state, the diaphragm is on its seat and the supply
pressure (P) is exhausted to vent (R). So output (A) is also in the ‘OFF’ state.
Since fluidic elements have no moving parts, they should theoretically last
indefinitely.
• If made of metal or ceramics, they can withstand high temperatures. The trouble,
however, is that fluidic elements are very sensitive to dirt. The slightest trace of
oil in the air supply can cause dirt build-up and eventual clogging.
• Due to insufficient attention, many of the industrial fluidic systems installed have
failed to perform reliably. This gave fluidics a reputation as being unreliable.

Pneumatic Logic Circuits

Two different types of pneumatic logic circuits are discussed here.

Pneumatic Logic Cylinder Sequencing Circuit

• The Fig. 13.17 is a pneumatic logic circuit which controls the extension and
refraction of two double acting cylinders. The sequencing is as follows: cylinder
A extends, cylinder B extends, cylinder A retracts and finally cylinder B retracts
(A WAW).
• The operation is as follows, assuming that both cylinders are initially fully
retracted. When the valve V is momentarily depressed, the pilot signal shifts pilot
valve V This causes cylinder A to extend. At full extension, limit valve V is
actuated to shift valve V and extend cylinder B. Upon full extension, limit valve
V is actuated.
 • This shif is valve V to retract cylinder A. Upon full retraction, limit valve V is
actuated. This shifts valve V to fully retract cylinder B. The cycle can be repeated
by subsequent momentary actuation of the Start push button valve V
Control of Pneumatic Cylinder Using Flip-Flop
• The Fig. 13.18 shows an application which provides for the push button start and
air limit-switch reversal of an air cylinder.
• Here the start and panic buttons represent back pressure sensors to allow 0.5 bar
restricted air supplies to activate the control ports of the flip-flop.