CHAPTER 4:
Introduction to Pneumatics &
Hydraulics System
Introduction
• Fluids or mechanism such as air and
oil have long been used to do What
work. is Oh No!!!
• Pascal's law states that pressurePLC?
applied on a confined fluid is
transmitted in all directions and acts
with equal force on equal areas and
at right angles to them.
• Most fluid power circuits use
compressed air or hydraulic fluid as
their operating media.
• Both systems are the same in many
aspects but have very different
characteristics in certain ways.
H. I. Jaafar 2
Definition of System
• Pneumatics: The use of a gas (in our case, air)
What is
flowing under pressure to transmit powerOh No!!!
PLC?
from one location to another.
• Hydraulics: The use of a liquid (oil, water, etc)
flowing under pressure to transmit power
from one location to another.
*Liquid in a hydraulic system behaves like a solid since it compresses very little
H.I. Jaafar DEKC3643 Chapter 4 3
Pneumatic System
• Low power -- 2 to 3 HP.
• 2 main advantages are low initial cost and
design simplicity.
• Always Clean.
• Leaks in an air circuit do not cause
housekeeping problems, but can cause
extra cost.
H.I. Jaafar DEKC3643 Chapter 4 4
Hydraulic System
• Circulates the same fluid repeatedly from a fixed reservoir.
• Hydraulic actuators can be controlled to very accurate positions,
speeds, or forces.
• Normally used mineral oil but other fluids such as water, ethylene
glycol, or synthetic types are not uncommon.
• Advantages: Greatly reduced noise levels at the machine & due to
operation at higher pressure (typically 1500 to 2500 psi), generate high
force from smaller actuators, which means less clutter at the work area.
• Main disadvantages of hydraulics is expensive first cost but often offset
by lower operating cost due to the much higher efficiency of hydraulics.
• Housekeeping problem caused by poor plumbing practices and lack of
pipe.
• More complex and require maintenance personnel with higher skills.
H. I. Jaafar 5
Example
H.I. Jaafar DEKC3643 Chapter 4 6
Example
What does PLC stand
for?
[Link]
H.I. Jaafar DEKC3643 Chapter 4 7
Pneumatic System
H.I. Jaafar DEKC3643 Chapter 4 8
Pneumatic System
• Typical pneumatic circuit :
Filter-Regulator-Lubricator
(FRL)
for clean air
• Power for a typical pneumatic circuit comes from a central
compressor facility with plumbing to carry pressurized air through
the plant.
H. I. Jaafar 9
Part of the Pneumatic System
The Compressor:
– Heart of the system.
– Converts electrical
energy to pneumatic
potential.
– Contains a relief valve
protects compressor
and system from
overload.
– Controlled by a Spike
relay.
H.I. Jaafar DEKC3643 Chapter 4 10
Part of the Pneumatic System
Air Tanks:
• Stores pressure to activate
actuators
Pressure Switch:
• Used to signal Robot
Controller when to turn on
and off compressor
H.I. Jaafar DEKC3643 Chapter 4 11
Part of the Pneumatic System
Regulators:
• Adjust pressure output to
working levels for actuators
• 2 types :
– Relieving and Non- Relieving
Fittings:
• Quick release and pipe
thread.
• Pipe thread requires Teflon
tape
H.I. Jaafar DEKC3643 Chapter 4 12
Part of the Pneumatic System
Valves & Solenoids:
• Used to control actuators
• Types:
– Double Solenoid (detented)
– Single Solenoid (spring
offset)
H.I. Jaafar DEKC3643 Chapter 4 13
Part of the Pneumatic System
Actuators
– Linear (often called
cylinders)
• Can be made to perform
complex motions by using
mechanical components
– Rotary
• Air Motors or turbines
H.I. Jaafar DEKC3643 Chapter 4 14
Hydraulic System
• Hydraulic systems have a power unit that only
operates one machine.
• Main difference for any hydraulic schematic with
pneumatic is at the power unit.
• The power unit consists of the reservoir, pump or
pumps, electric motor, coupling and coupling
guard, and entry and exit piping, with flow meters
and return filter.
• It also might include relief valves, unloading
valves, pressure filters, offline filtration circuits,
and control valves.
H.I. Jaafar DEKC3643 Chapter 4 15
Typical Hydraulic Circuit
Accumulator
Power Unit Circuit example
H.I. Jaafar DEKC3643 Chapter 4 16
Cont..
• Pressure-control valves: A pressure-relief valve at the pumps
automatically protects the system from overpressure. (Also
exist in pneumatic system)
• Reservoir: The hydraulic fluid reservoir holds excess hydraulic
fluid to accommodate volume changes from cylinder
extension and contraction, temperature driven expansion
and contraction, and leaks.
• Generally Reservoirs provide a location for storage of the
motive media (hydraulic fluid or compressed gas).
• Accumulators: Because hydraulic oil is almost non-
compressible, a gas-charged accumulator allows for storage
of a volume of fluid to perform work. The expandable gas in
the accumulator pushes the oil out when external pressure
tries to drop.
H. I. Jaafar 17
Pneumatics VS Hydraulics
System Characteristic Hydraulic System Pneumatic System
1) Pressurized fluid Oil (or Water-Oil Emulsion) Compressed air
2) Compressibility Incompressible Compressible
3) Typical applied by devices High Low
4) Actuation speed of
Low High
devices
5) Speed control Accurate speed control Difficult to control accurately
6) Problem with fluid leaks Yes, potential hazard No problem when air leaks
Close tolerances and good O-rings used to prevent leaks
7) Device construction and
surface finishes required on instead of highly accurate
manufacture
components components
Preferred when high forces Preferred when low cost and
8) Automation applications and accurate control are high speed actuation are
required required
H.I. Jaafar DEKC3643 Chapter 4 19
Actuators
• Linear actuator: A cylinder (linear
motor) that used to give a linear
force through a linear stroke.
• Classified according to construction
and method of operation.
• 2 types: Single acting and double
acting.
• Normally, single acting cylinder has
a spring to return the piston rod. Air
or oil used to extend the cylinder
and when the pressure is released,
the spring returns the piston.
H.I. Jaafar DEKC3643 Chapter 4 20
Actuators
• Double acting cylinder uses air to extend and retract the
piston.
H.I. Jaafar DEKC3643 Chapter 4 21
Two types of
Pneumatic/Hydraulic Actuators
• Cylinders with piston driven by
pressurized fluid
• Single acting cylinder (SAC)
• Double acting cylinder (DAC)
H.I. Jaafar DEKC3643 Chapter 4 22
Cylinder & Piston
(a) Single Acting with Spring Return and (b) Double Acting
H.I. Jaafar DEKC3643 Chapter 4 23
Valve Symbol Structure
• Position represented by squares.
• No. of squares represents the number of switching positions.
• Lines & Arrows in the boxes indicate flow & direction of paths.
• Directional control valves are represented by the number of
ports and control position they have.
• Normally open and normally closed (locked) are the opposite
in fluid power.
H.I. Jaafar DEKC3643 Chapter 4 24
Valve Symbol Structure
• A 3/2 valve: Therefore, it has 3 ports (normally
these are inlet, outlet and exhaust) and 2 states
(the normal state and the operated state)
• The boxes are two pictures of the same valve
operated normal
H.I. Jaafar DEKC3643 Chapter 4 25
Valve Symbol Structure
• A valve symbol shows the pictures for each of the
valve states joined end to end.
operated normal
H.I. Jaafar DEKC3643 Chapter 4 26
Valve Symbol Structure
• A valve symbol shows the pictures for each of the
valve states joined end to end.
operated normal
H.I. Jaafar DEKC3643 Chapter 4 27
Valve Symbol Structure
• The port connections are shown to only one of
the diagrams to indicate the prevailing state.
normal
H.I. Jaafar DEKC3643 Chapter 4 28
Valve Symbol Structure
• The operator for a particular state is illustrated
against that state.
Operated state
produced by
pushing a button
H.I. Jaafar DEKC3643 Chapter 4 29
Valve Symbol Structure
• The operator for a particular state is illustrated
against that state.
Operated state Normal state
produced by produced by
pushing a button a spring
H.I. Jaafar DEKC3643 Chapter 4 30
Valve Symbol Structure
• The operator for a particular state is illustrated
against that state.
Operated state Normal state
produced by produced by
pushing a button a spring
H.I. Jaafar DEKC3643 Chapter 4 31
Valve Symbol Structure
• The valve symbol can be visualised as moving to
align one state or another with the port
connections.
H.I. Jaafar DEKC3643 Chapter 4 32
Valve Symbol Structure
• The valve symbol can be visualised as moving to
align one state or another with the port
connections.
H.I. Jaafar DEKC3643 Chapter 4 33
Valve Symbol Structure
• The valve symbol can be visualised as moving to
align one state or another with the port
connections.
H.I. Jaafar DEKC3643 Chapter 4 34
Valve Symbol Structure
• A 5/2 valve symbol is constructed in a similar way.
A picture of the valve flow paths for each of the
two states is shown by the two boxes. The 5
ports are normally an inlet, 2 outlets and 2
exhausts.
H.I. Jaafar DEKC3643 Chapter 4 35
Valve Symbol Structure
• The full symbol is then made by joining the two
boxes and adding operators. The connections are
shown against only the prevailing state.
H.I. Jaafar DEKC3643 Chapter 4 36
Valve Symbol Structure
• The full symbol is then made by joining the two
boxes and adding operators. The connections are
shown against only the prevailing state.
H.I. Jaafar DEKC3643 Chapter 4 37
Valve Symbol Structure
• The full symbol is then made by joining the two
boxes and adding operators. The connections are
shown against only the prevailing state.
H.I. Jaafar DEKC3643 Chapter 4 38
Valve Functions
Basic valves before Examples, push button operated
operators are added with spring return
Normal position
Function 2/2
Function 3/2
H.I. Jaafar DEKC3643 Chapter 4 39
Valve Functions
Basic valves before Examples, push button operated
operators are added with spring return
Operated position
Function 2/2
Function 3/2
H.I. Jaafar DEKC3643 Chapter 4 40
Valve Functions
Basic valves before Examples, push button operated
operators are added with spring return
Normal position
Function 4/2
Function 5/2
H.I. Jaafar DEKC3643 Chapter 4 41
Valve Functions
Basic valves before Examples, push button operated
operators are added with spring return
Operated position
Function 4/2
Function 5/2
H.I. Jaafar DEKC3643 Chapter 4 42
Valve Functions 5/3
l All valves types shown in the normal position
l Type 1. All ports sealed
l Type 2. Outlets to exhaust
l Type 3. Supply to outlets
H.I. Jaafar DEKC3643 Chapter 4 43
Valve Functions 5/3
l All valves types shown in the first operated position
l Type 1. All ports sealed
l Type 2. Outlets to exhaust
l Type 3. Supply to outlets
H.I. Jaafar DEKC3643 Chapter 4 44
Valve Functions 5/3
l All valves types shown in the normal position
l Type 1. All ports sealed
l Type 2. Outlets to exhaust
l Type 3. Supply to outlets
H.I. Jaafar DEKC3643 Chapter 4 45
Valve Functions 5/3
l All valves types shown in the second operated position
l Type 1. All ports sealed
l Type 2. Outlets to exhaust
l Type 3. Supply to outlets
H.I. Jaafar DEKC3643 Chapter 4 46
Valve Functions 5/3
l All valves types shown in the normal position
l Type 1. All ports sealed
l Type 2. Outlets to exhaust
l Type 3. Supply to outlets
H.I. Jaafar DEKC3643 Chapter 4 47
Several Common Valve
Actuation Types
H.I. Jaafar DEKC3643 Chapter 4 48
How it Function
What does PLC stand
for?
[Link]
H.I. Jaafar DEKC3643 Chapter 4 49
That’s all … TQ
H.I. Jaafar DEKC3643 Chapter 4 50