BASICS OF PNEUMATICS

Composition of air
Air is composed
mainly of nitrogen
and oxygen

Composition by Volume
Nitrogen 78.09% N2
Oxygen
20.95% O2
Argon
0.93% Ar
Others
0.03%

Pressure

1 bar = 100000
N/m2 (Newtons
per square metre)
1 bar = 10 N/cm2

Pressure is defined as
force acting per unit
area
For measuring lower
pressures the millibar
(mbar) is used
1000 mbar = 1 bar
For measurements in
pounds per square
inch (psi)
1 psi = 68.95mbar
14.5 psi = 1bar

When we are applying

force to the normal air, it
will get compressed
Normally in industrial
application the range of
pressure will be 6 10
bar
For special application
like testing and in
submarine application
high pressure is used.

17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0

Gauge pressure bar g

Absolute pressure bar a

Compressed air
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0

Extended
Industrial
range
Typical
Industrial
range
Low
range

Atmosphere
Full vacuum

Pressure units

There are many units of pressure measurement.

Some of these and their equivalents are listed
below.

1 bar = 100000 N/m2

1 bar = 100 kPa
1 bar = 14.50 psi
1 bar = 10197 kgf/m2
1 mm Hg = 1.334 mbar approx.
1 mm H2O = 0.0979 mbar approx.
1 Torr = 1mmHg abs (for vacuum)
More units of pressure

Flow units

Flow is measured as a volume

of free air per unit of time
Popular units are :
Litres or cubic decimetres per
second
l/s or dm3/s
Cubic metres per minute
m3/m
Standard cubic feet per
minute (same as cubic feet of
free air) scfm

1 cubic foot
1 litre or
cubic decimetre

1 m3/m = 35.31 scfm

1 dm3/s = 2.1 scfm
1 scfm = 0.472 l/s
1 scfm = 0.0283 m3/min

1 cubic metre
or 1000 dm3

Free air flow

The space between the bars

represents the actual volume
in the pipe occupied by 1 litre
of free air at the respective
absolute pressures.
Flow takes place as the result
of a pressure differential, at
1bar absolute (0 bar gauge)
there will be flow only to a
vacuum pressure
If the velocity were the same
each case will flow twice the
one above

Actual volume of 1 litre

of free air at pressure
0
1 litre
1bar a
1

2bar a
1

4bar a
/8

8bar a
/16

16bar a

/4

/2

COMPRESSED AIR
WHEN THE AIR REACHES THE
PRESSURE MORE THEN
ATMOSPHERIC PRESSURE(1 BAR) IT
IS CALLED AS COMPRESSED AIR.

APPLICATION OF COMPRESSED AIR

MINING AND CONSTRUCTION INDUSTRY.

BOTTLING INDUSTRY.
ROLLING MILLS & FOUNDRIES.
AUTOMOTIVE INDUSTRIES.
INDUSTRIAL AUTOMATION.
MACHINE TOOLS.
HAND TOOLS.
OTHERS.

TYPES OF COMPRESSORS

COMPRESSORS

POSITIVE DISPLACEMENT

RECIPROCATING

SCREW

TWIN LOBE

DYNAMIC

ROTARY

CENTRIFUGAL

AXIAL

RECIPROCATING
COMPRESSOR

As the piston descends,

increasing the available
space, the decrease in
pressure causes the
inlet valve to open and
air to be drawn into the
compressor chamber.

Subsequently, after the

piston has passed its
turning point
corresponding to the
maximum volume of the
compressor chamber, the
inlet valve closes as the
air pressure starts to
increase.

As the volume of the

compression chamber
decreases, the air
pressure increases.

Finally, when the

pressure has reached a
pre-determined value,
the discharge valve
opens, and the
compressed air leave the
compression chamber.

RECIPROCATING AIR COMPRESSOR

RECIPROCATING COMPRESSOR CONSIST OF FOLLOWING MAIN PARTS

1.MOTOR
2.CRANK.
3.PISTON ROD

4.PISTON.
5.PISTON RINGS.
6.SUCTION FILTER

6.INLET VALVE
8.EXHAUST VALVE
9.NON RETURN VALVE.

10.AIR RESEVOIR.
11.SAFETY VALVE.

IN RECIPROCATING AIR COMPRESSOR MOTOR WILL DRIVE THE CRANK BY PULLEY.CRANK WILL ROTATE AND MOVE THE
PISTON ROD TO UP AND DOWN .WHILE MOVING DOWN, PISTON CONNECTED TO PISTON ROD SUCKS THE AIR THROUGH
INLET VALVE.AGAIN DUE TO CRANK ROTATION PISTON MOVES UP AND COMPRESS THE AIR.THE COMPRESSED AIR MOVES
THE EXHAUST VALVE UP AND ESCAPES.PISTON RINGS ARE PROVIDED AROUND PISTON INORDER TO SEAL THE
COMPRESSED AIR AND LUBRICATE THE CYLINDER.SUCTION FILTER IS PROVIDED IN ORDER TO ALLOW CLEAN AIR TO
CYLINDER.NON RETURN VALVE IS PROVIDED INORDER TO PREVENT THE REVERSE FLOW OF COMPRESSED AIR. THE
COMPRESSED AIR WILL GET FILLED IN THE AIR RESERVOIR UNIT.AIR RESERVIOR UNIT IS PROVIDED IN ORDER TO SUPPLY
CONSTANT FLOW OF AIR TO THE LINE. A SAFETY VALVE (PRESSURE RELIEF VALVE) IS PROVIDED IN THE RESERVOIR
FOR SAFETY PURPOSE .IF COMPRESSOR EXCEEDING THE DESIRED PRESSURE RELIEF VALVE GET OPENED UP AND
PRESSURE WILL GO DOWN .FOR LUBRICATION A LUBRICATION SCOOP IS USED IN SMALL COMPRESSORS.FOR LARGE
COMPRESSORS A SAPERATE LUB PUMP WILL BE PROVIDED.

COMPRESSOR
SCREW

Screw compressor consists of two rotors, one male rotor and one female rotor. The male rotor has four
equally spaced helical lobes. The rotors used have asymmetrical rotor profiles. This type of profile allows the
female rotor to be driven directly by the male rotor, avoiding the need for synchronizing gearwheels.
Because the rotary screw compressor uses the positive displacement principle, the air delivery is directly
proportional to the rotation speed. The higher the speed, the larger the volume displaced by the compressor
element

1- The ends of the rotors uncover the inlet and air enters the compression chamber.
2- The air is entrapped in the 'compartment' formed by a male lobe and a female flute.
3- As the rotors turn, the compartment becomes progressively smaller, thereby compressing the entrapped air.
4- Compressed air leaves through the outlet port

Intake air.

Air.

Air/Oil mixture

Wet Air.

Refrigerant.

Oil

Air flow : 1.Air intake filter - 2.Air intake valve - 3.Compression element - 4.Non-return valve - 5.Oil separator element 6.Minimum pressure valve - 7.After cooler - 8.Air to air heat exchanger - 9.Water separator with drain- 10.Filter (optional)

Oil flow : 11.Oil reservoir - 12.Oil cooler - 13.Thermostatic bypass valve - 14.Oil filter - 15.Oil stop valve
Refrigeration flow : 16.Refrigerant compressor - 17.Condenser - 18.Liquid refrigerant dryer/filter - 19.Capillary tube 20.Evaporator - 21.Hot gas bypass valve - 22.Accumulator

PRECAUTION IN HANDLING THE COMPRESSORS

BEFORE OPENING ANY PARTS INSIDE THE COMPRESSOR

UNLOAD ALL THE PRESSURISED AIR AND ENSURE NO
PRESSURE INSIDE COMPRESSOR.
NEVER TOUCH THE LIVE WIRE INSIDE THE COMPRESSOR.
BEFORE OPENING THE INSIDE PARTS OF COMPRESSOR
NEVER FORGET TO CLOSE THE OUTLET VALVE.
TEMPERATURE OF THE COMPRESSED OIL IS MORE.SO
BEFORE CHANGING THE OIL ALLOW IT TO COOL.
NEVER ADJUST THE SAFETY VALVE SETTING.
DONT CHANGE THE PARAMETER SETTING UNTIL
OTHERWISE IT IS VERY MUCH ESSENTIAL.

NEVER ALLOW AIR LEAKAGE ANYWHERE

A SMALL CALCULATION ON AIR LEAKAGE.
CONSIDER OUR BIG COMPRESSOR (NO 1) IS RUNNING.
CAPACITY OF COMPRESSOR - 75 KW.
VOLUME PRODUCED BY COMPRESSOR - 500 CFM.
CONSIDER IF AIR IS LEAKING FROM BSP PIPE.
VOLUME OF AIR LEAKING AT 6 BAR PRESSURE - 94 CFM.
FOR PRODUCING 500 CFM IT NEEDED 75 KW.
TO PRODUCE 94 CFM IT REQUIRE AROUND 14.25 KW/HR
FOR ONE YEAR SAY COMPRESSOR IS LOADED FOR 3000 HRS.
SO IT CONSUME 14.25 X 3000 = 42,750 UNITS YEARLY.

NEARLY 2.5 LACS + EXTRA COST IS LOST FOR COMPANY.

SO NEVER ALLOW AIR LEAKAGE IN COMPANY.

PRESSURE REGULATOR

DIRECTION CONTROL VALVE AND SILENCER

FILTER REGULATOR- LUBRICATOR

FLOW CONTROL VALVE

FRLs

FRL stands for filter, regulator and lubricator

When an FRL unit is referred to, it means a combination
of these three devices closely connected together
They form a unit that will prepare the condition of
compressed air just before delivering it to pneumatic
equipment or machinery
This ensures the air supply is clean and dry, the
pressure is at the correct level and fine particles of oil
are carried in the air to lubricate the wearing parts
within valves, cylinders and tools
A convenient method of combining these components
is to use a modular system

Filter (general principle)

SYMBOL

LOUVER

FILTER

WATER PARTICLES

DRAIN PLUG

Separate and collect

contaminants
Angled louvers spin the
air as it enters the bowl
Water droplets and large
solid particles spun
outwards against bowl
and run to the bottom
Baffle prevents turbulent
air splashing water on to
the filter element
Element traps finer solid
particles

Compressed air quality

ISO 8573-1
Class

1
2
3
4
5
6
7

Solids

Water

Oil

particle concentration
size max maximum
m
mg/m 3

Max Pressure
Dew point OC

concentration
mg/m 3

70
40
20

0.01
0.1
1
5
25
-

0.1
1
5
15
40
-

0.1
1
5
8
10
-

+3
+7
+ 10
Not Specified

Pressure dew point is the temperature to

which compressed air must be cooled before
water vapour in the air starts to condense into
water particles

Pressure regulator

4
2

40

80
120

lbf/in2
bar

10

P1

P2

This is a relieving regulator

to allow pressure to be
reduced to a lower setting
Turn anticlockwise to
reduce the spring force
The higher force under the
diaphragm lifts it clear of
the valve spindle
P2 can now exhaust until
the diaphragm seals
Turn clockwise to adjust
up to the new pressure

Pressure regulator

4
2

40

80
120

lbf/in2
bar

10

P1

P2

Reduces supply pressure

P1 to a suitable working
pressure P2
When there is no flow
demand the poppet valve
closes to hold the
pressure at P2
Flow demand will open the
poppet valve wide enough
to satisfy the flow rate at
pressure P2
P2 can be set on a gauge
fitted to the regulator

Pressure regulator

4
2

80
40
120
lbf/in2
bar

10

P1

P2

To increase pressure P2,

pull the adjusting knob up
to disengage the locking
teeth
Turn clockwise until new
P2 pressure reached
The higher spring force
pushes the valve open
The rising pressure P2
acts under the diaphragm
to balance the spring and
allow the valve to close

Filter Regulator

Filter and regulator

designed as a single unit
Air is first filtered then
directed to the primary
side of the regulator
Pressure is then reduced
to a working value
Only one unit to install
Cost saving when
compared to two separate
units

Lubrication

Been for efficient running of pneumatic equipment and

long life of seals and wearing surfaces, correct lubrication
is essential
For the best results light lubrication is applied
continuously from an air line lubricator. This is particularly
relevant in adverse applications where there may be high
speed and high temperature running or where the
condition of the compressed air has poor
In a lubricator, oil drips are atomised and the tiny oil
particles form a very fine mist in the air supplying the
application

Lubricator Unit

P2

P1

P2

P1

Oil is sucked in yellow tube by

its pressure difference. Its
flow will be controlled by
green knob at top side.
Oil will drip as droplet and it will
become small droplet and
mixes at delivery air.
Normally recommended oil is
VG 32.

Valve Types

Function is the switching

complexity of a valve
Shown by two figures 2/2,
3/2, 4/2, 5/2, 3/3, 4/3 & 5/3
First figure is the number of
main ports. Inlets, outlets, and
exhausts excluding signal
and external pilot supplies
Second figure is the number
of states
A 3/2 valve has 3 ports, and 2
states, normal and operated.

DIRECTION CONTROL VALVE

Valve Size

Size refers to a valves port

thread.
For similarly designed
valves the amount of air
flow through the valve
usually increases with the
port size.
Port size alone however
cannot be relied upon to
give a standard value of
flow as this is dependent on
the design of the valve
internals.

The port size

progression M5,R1/8 ,
R1/4, R3/8 , R1/2, R3/4,
R1.
R/
3

M5

R /8
1

R1/2

R1/4

R1

R3/4

Actuator Control (3/2 valve)

12

10

12
3

10

A 3 port valve provides the inlet, outlet and exhaust path and is the normal
choice for 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 for as long as the cylinder is outstroked

Actuator Control (5/2 valve)

4
14

12
5

14

12
5

1 3

A five port valve provides an inlet port 1 that is switched between

two outlet ports 2 and 4 each with an exhaust port 3 & 5
In the normal position produced by the spring 1 is connected to 2
with 4 to exhaust 5
In the operated position produced by pushing the button port 1 is
connected to 4 with 2 to exhaust

5/3 Valve (open exhausts)

With the spool in the mid (normal) position the supply port is sealed
and outlet ports are to exhaust
Spool right, port 1 is joined to 4, port 2 is joined to 3
Spool left, port 1 is joined to 2, port 4 is joined to 5
4

1 3

14

12
5

5/3 Valve (open exhausts)

With the spool in the mid (normal) position the supply port is sealed
and outlet ports are to exhaust
Spool right, port 1 is joined to 4, port 2 is joined to 3
Spool left, port 1 is joined to 2, port 4 is joined to 5
4

1 3

14

12
5

5/3 Valve (open exhausts)

With the spool in the mid (normal) position the supply port is sealed
and outlet ports are to exhaust
Spool right, port 1 is joined to 4, port 2 is joined to 3
Spool left, port 1 is joined to 2, port 4 is joined to 5
4

1 3

14

12
5

Typical Valve

Identification of the
component parts of a
typical 5/2 solenoid valve
with spring return

Pressure indicator
Alternative ports 2, 4

Manual override
Electric connectors
9

Return spring

SOLENOID

PISTON
Valve body

Spool with disc seals

Pilot operated 2/2 seat valve

Springs provide excellent

sealing in the normally closed
position
Air pilot signal lifts the seat
against the spring
AIR PILOT
In sizes G1/2 to G2 for high
flow
Suitable for vacuum to up to SPOOL WILL LIFT WHEN AIR
ENTERD IN TO PILOT
16 bar
Can be close connected with
a solenoid pilot valve to
generate the pilot signal
INLET
Click the illustration to start and stop animation

Flow Regulation

By the use of flow

regulators the outstroke
speed and instroke speed
of a piston rod can be
independently adjusted
Speed is regulated by
controlling the flow of air to
exhaust
The front port regulator
controls the outstroke
speed and the rear port
regulator controls the
instroke speed

Flow regulator

Uni-directional, line mounted adjustable flow regulator

Free flow in one direction
Adjustable restricted flow in the other direction

Banjo Flow Regulator

Designed to fit directly in to

cylinder ports, so placing
adjustment at the appropriate
cylinder end
Two types:
One to give conventional
flow restriction out of the
cylinder and free flow in
(as illustrated)
The other type to give
restricted flow in to the
cylinder and free flow out
(not illustrated)

Guide to Valve Size and Flow

This graph gives a guide to the to flow range appropriate to different valve
sizes
Port size alone can only be a rough guide, individual valve types will vary
according to design
The flow values indicated by the vertical lines are
at P1 = 6 bar, with 1bar pressure drop

R1
R3/ 4
1
Valve R /2
3
size R /8
R1/ 4
R1/ 8
M5
250 1250
750

2500

4250

6000

Flow l/min

10000

Introduction To Actuators
Pneumatic actuators include linear cylinders
and rotary actuators.
They are devices providing power and motion to
automated systems, machines and processes.
A pneumatic cylinder is a simple, low cost, easy
to install device that is ideal for producing
powerful linear movement.
Speed can be adjusted over a wide range.

A cylinder can be stalled without damage.

Introduction To Actuators

Adverse conditions can be easily tolerated such as high

humidity, dry and dusty environments and cleaning
down with a hose.
The bore of a cylinder determines the maximum force
that it can exert.
The stroke of a cylinder determines the maximum linear
movement that it can produce.
The maximum working pressure depends on the
cylinder design. VDMA cylinders work up to 16 bar.
Thrust is controllable through a pressure regulator.

Basic Construction
1 cushion seal
2 magnet
3 cushion sleeve
4 barrel
5 guide bush
6 rod and wiper seal
7 front end cover
8 front port
9 reed switch
10 piston rod
11 wear ring
12 piston seal
13 rear end cover
14 cushion screw

cushion seal
magnet
1

2
3

14

4
5
6

13
12
11
10
9
8
7

Single acting

Single acting cylinders have

a power stroke in one

Normally in
Normally out

direction only

Click the illustrations to start and stop animation

Double acting cylinder

Double Acting Cylinder Without Cushion

Double Acting Cylinder With Fixed Cusion.

D/A adjustable cushions

progressively slows the piston rod down over the last part of stroke

Fixed cushion design

Shock absorbent discs set into the end covers
cushion the impact of the piston

Adjustable cushion design

The piston is moving to the left at speed.
Air is venting through the centre of the seal.

Adjustable cushion design

The cushion seal is pushed to the left and seals against its left hand edge
and inside diameter.
Air can only escape past the cushion screw. The pressure builds up and
cushions the piston.

Adjustable cushion design

The screw is set to bring the piston, rod and load to a gentle halt
against the end cover.

Adjustable cushion design

A valve has been operated to power the piston out.

The cushion seal is pushed to the right. Grooves in the right hand
edge and outside diameter bypass the screw.

Adjustable cushion design

The piston is started in the other direction un-restricted by the

cushion screw setting.

Rodless cylinders

Contain the movement produced within the same

overall length taken up by the cylinder body.
For example, action across a conveyor belt, or for
vertical lifting in spaces with confined headroom.
Movement is from a carriage running on the side of the
cylinder barrel.
A slot, the full length of the barrel allows the carriage to
be connected to the piston.
Long sealing strips on the inside and outside of the
cylinder tube prevent loss of air and ingress of dust.
Click the illustration to start and stop animation

Rodless cylinder
Double acting with adjustable cushions

Click the illustration to start and stop animation

Operating principle

The sealing strips are parted and closed as the

piston moves through the stroke
Adjustable cushions
Dual connection ports at the left hand end

Click the illustration to start and stop animation

LINTRA applied

For action across a

strip process
No overhang or
mechanism required
compared to a
conventional piston
rod cylinder
The application shows
a flying knife typical of
use in the paper
production industry
Click the illustration to start and stop animation

Maintenance of pneumatic systems

Checking points in pneumatic system

1.

Drain the water from filter.

2.

Check the air pressure in pressure gauge. it should be in setting pressure.

3.

Ensure the oil level in lubricator unit.

4.

Ensure any air leakage in ,Air guns,FRL unit,Valves,hoses, pipe lines, fittings etc.

5.

Ensure the oil dropping ,whether it is normal or ant disturbances.

6.
7.

Check any oil leakage in lubricator unit.

Ensure any crack or damage in air hoses.

8.

Clean the filter unit.

9.

Remove any dirt in lubricator unit.

BELT DRIVES

Drain the water

Check the pressure

Clean the silencer

twice in a month

Check the oil level

in lubricator
No oil in lubricator