MEM341: FLUID POWER TECHNOLOGY

9.

Pneumatics

Introduction
Pneumatic systems use pressurized gases to transmit and control power (air). Air because it is a safe, low cost, and easily available fluid. Why we chose pneumatic systems? Gases have smaller inertia compared to liquids (acceleration, deceleration, sudden movement such as opening valves). Gases have lower viscosity (less friction forces). Do not require a return line. But air is compressible. Precision of control is less compared to hydraulic systems. Pneumatic is for low-power applications.

Properties of Air
Air is a mixture of gases (21% O2, 78% N, 1% other gases), moisture and other impurities. When making pneumatic circuit calculation, we used standard atmospheric conditions 20 0C, 101 kPa abs and 11.8 N/m3.

The Perfect Gas Laws

! PERFECT GAS DO NOT EXIST IN REALITY ! But air behaves vary closely to that of a perfect gas.

Boyles Law
States that if the temperature of a given amount of gas is held constant, the volume of the gas will change inversely with the absolute pressure of the gas.

V1 p2 = V2 p1
Charless Law
States that if the pressure on a given amount of gas is held constant, the volume of the gas will change in direct proportion to the absolute temperature.

V1 T1 = V2 T2
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Gay-Lussacs Law
States that if the volume of a given gas is held constant, the pressure exerted by the gas is directly proportional to its absolute temperature.

p1 T1 = p 2 T2

General Gas Law

It is the combination of Boyles, Charles and Gay-Lussacs Laws into a single general gas law.

p1V1 p 2V2 = T1 T2
PNEUMATIC COMPONENTS Compressors
Compressor is a machine that compresses air (gases) from a low inlet pressure to a higher desired pressure level. Generally used positive displacement pump (piston, rotary vane or rotary screw).

Figure: Different types of compressor design.

When air is compressed, heat will be generated because of the molecules of air come closer together, excessive heat will damage the components. Active cooling is used such as fan or water cooling. Single piston normally can efficiently achieve compressed pressure of 150 psi (10 bars). To achieve higher pressure can used more than one cylinder. Multi-stage compressors are more efficient.

Figure: Multi-stage compressor

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MEM341: FLUID POWER TECHNOLOGY Compressors operate by initially bring the pressure in the tank to the desire pressure. After that, will automatically control the pressure inside by starting and stopping pump when needed unloading control (pressure switch type or a centrifugal type).

Air Receivers
Main function is to store air from compressor and supply air to the system at constant pressure and as the storage unit for compressed air. It also functions to dampen pressure pulse/surge. Sizing of air receiver; 101 (time that the receiver can supply required amount of air) (system consumption rate compressor output flow rate) ( max receiver pressure min receiver pressure) Commonly air receivers are design to a larger size to accommodate future expansion.

Receiver size, Vr =

Figure: Air receiver and cut-away diagram of a typical air receiver.

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FLUID CONDITIONING Air Filters

function of an air filter is to remove contaminants, 5 50 micron meter.

Air Pressure Regulators

to regulate the pressure coming out from air receiver and ensure that a constant pressure is supply to the pneumatic system.

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Air Lubricators
add lubricant(oil mist) to the air supply to pneumatic system. This is to ensure that proper lubrication to the internal moving parts of pneumatic components.

Pneumatic Pressure Indicators

to give visual indication, whether inside the pneumatic system/hoses/components are supply with compressed air or not.

After-coolers
to remove moisture from compressed air before enter receiver. Basically a type of heat exchanger. It also functions to cool the air to operating temperature. Effectively remove ~85% of moisture in the air.

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Air Dryer
Remove virtually all moisture from compressed air The air coming out of this component is basically free of moisture dry air. It is installed after air-cooler. 3 basic types available: o Chemical using chemical reaction to remove moisture (chalk, calcium chloride) o Adsorption using material such as silica gel. o Refrigeration using chiller dryers unit, just like in a air condition system.

Service Units
A system that combine filter, moisture, pressure regulator, and lubricator (FRL) into a single unit.

Figure: Service unit, from left to right, filter, pressure regulator and lubricator. Pneumatic Silencers used to control the noise level cause by the exhausting air stream to the environment.

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PNEUMATIC CONTROL VALVES Air Flow-rate Control with Orifice

air flow-rate is control by creating flow restriction. Bernoulli Effect.

Q = 0.0698 C v
Where,

( p1 p 2)( p 2)
T1

Q is air flow-rate in m3/min p1 is upstream pressure in absolute pressure kPa p2 is downstream pressure in absolute pressure kPa T1 is upstream air temperature Cv is flow capacity constant Only valid when, p2 > 0.53 p1 because beyond this the air flow is choked, where air speed reach the speed of sound.

Pressure Regulators
function to control the pressure enter each pneumatic circuit.

Check Valves
allow flow in one direction only it function to control flow direction.

Shuttle Valves
automatically selects the higher of two input pressures and connects that pressure to the output port. 82

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Directional Control Valves (DCV) OUTPUT DEVICES ACTUATORS Pneumatic Cylinders working principal are just like hydraulic cylinder. Design are more simple and lightweight than hydraulic cylinder. many types of design. Control the direction of air travel. Different ways of actuating the valves; air pilot, roller, push button, plunger, detent, spring, level, solenoid etc.

Air Motor mostly based on vane type construction. Can provide infinite torque and speed. Can start and stop quickly. Can be stall with out concerned for heat buildup. Higher speed relate to lower torque, and vice-se-versa.

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Basic Pneumatic Circuits 1. Operation of a single acting cylinder

Service unit

Single acting cylinder with spring return

Flow control valve 3-way, 2position spring offset push button DCV

2. Operation of a double-acting cylinder

Double acting cylinder

Service unit

5-way, 2-position spring offset push button DCV

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3. Air pilot control of a double acting cylinder

5/2 pilot actuated DCV

Pressure regulator

4. Cylinder cycle timing system

Limit valve/Limit switch

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5. Two step speed control system

Shuttle valve will connect the inlet port with higher pressure to the outlet port.

Combination of limit valve and pilot operated DCV will divert the compressed air flow through either flow control valve V3 or V4.

6. Two handed safety control circuit. To extend the cylinder, both push button V1 and V2 must be press together.

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7. Control of an air motor using two push buttons to start or stop the air motor.

8. Deceleration air cushion of a pneumatic cylinder.

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Pneumatic and Hydraulic System 1. Air-oil system for speed control

Oil cylinder is used to control the speed of the air cylinder. Often called a hydraulic-check system. This will enable a slow, control, smooth control to be achieved on the air cylinder.

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2. Air-oil reservoir system

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3. Two air-oil reservoirs used to control a double acting oil cylinder

4. Air-oil intensifier
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Appendices:
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Figure: Commonly used direction valves.

Figure: Examples of centre positions.

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