Pneumatic & Hydraulics System

Design

Dr. Nageswara Rao Atyam

Associate Professor, Defence & Aerospace Technology
Symbiosis Skills & Professional University, Pune.
Introduction
• It is a technology which deals with power of air.

• In pneumatics, air is 'empowered' by compressing it and then its power is used to obtain mechanical advantage i.e.
to do useful works.

• The use of air power was known to man from IInd World War. The industrial automation is done by using power of
compressed air. The deburring tools, fettling tools are pneumatic tools.

• Pneumatic power is used widely in food processing industry. You might have visited a soft drink factory. In this
factory, the movement of glass/plastic bottles are achieved in disciplined manner by using compressed air
operated mechanisms called pneumatic circuits.

• In foundry, the casting needs cleaning. This cleaning operation is popularly known as fettling. In short, fettling is
casting cleaning operation. To clean the surface of casting we need tools like straight grinders, angle grinders. These
tools operate on pneumatic power.
Con…
• In road asphalting (making tar roads) process, we have to chip-off, the existing tar road. This chipping of the hard road is
done by pneumatic chipper, which operates on compressed air power. The air is supplied to chipper by engine driven air
compressor installed on truck or tractor.

• Similar example is as that of drilling the bore-well in ground. This drilling-rig operates on pneumatic power supplied by
engine driven air compressor installed on truck.

• In printing press, especially on offset printing machine, you might have observed that, the single paper is lifted by plastic
'bellow' and is fed to machine for printing. This paper handling is a miracle of compressed air. In this mechanism, jet creates
vacuum in 'bellow', to which single paper 'sticks' temporarily and when vacuum collapses, the paper is released.

• Siron which creates big sound to indicate 'lunch-recesses' timings to factory workers is another miracle of compressed air.

• This list is un-ending. In each industry, use of compressed air is becoming unavoidable. So we must understand, how
pneumatic power is used.
Features of Air:
• Power of Air has became so popular in industry automation, tools etc. because of some features of air (characteristics of air),
which could not be found with any other medium. These important and notable features of air are as given below:

• Air is available free of cost.

• Wide availability of air.

• Air is absolutely fire proof (no danger of fire).

• Easy transportability i.e. through pipes.

• Easy storage i.e. in air receivers.

• The construction of pneumatic equipment is comparatively easy.

• The maintenance cost of equipment is low and maintenance is easy.

• The overall cost of compressed air and pneumatic equipment is low.

General Layout
of Pneumatic
System
 Con…
This diagram represents a typical pneumatic system used for powering actuators
and other pneumatic devices. Atmospheric air first enters the compressor, where
it is pressurized and then stored in an air receiver tank to ensure a steady supply.
From the storage, the compressed air passes through a moisture separator that
removes condensed water and then through an air filter that eliminates dust and
other impurities. The pressure regulator ensures that the air is maintained at a
constant working pressure suitable for downstream components, while the
lubricator adds a fine mist of oil to reduce wear and friction in moving parts. In
some systems, an additional air dryer is employed to completely remove
moisture and prevent corrosion or freezing. The conditioned air is then directed
through control valves, which regulate and control the flow of compressed air to
the actuator. Finally, the actuator converts the energy of compressed air into
useful mechanical motion—either linear or rotary—and the used air is exhausted
to the atmosphere. This sequence ensures that the air delivered to the actuator is
clean, dry, lubricated, and at the correct pressure, which improves the reliability,
safety, and efficiency of pneumatic operations.
Con…
• Compressor: This unit compresses the air which is at atmospheric pressure. Due to
compression the pressure of air increases. This unit run either on electric motor or on
diesel/petrol engine or gas/steam turbine.
• The compressors used in Engineering units/foundry are either reciprocating or screw
compressor and runs on electric motors.
• The compressors used for 'bore well' machine are generally screw compressors and runs on
diesel engine or directly on truck or tractor engine on which they are mounted.
• The compressors in sugar factory runs on steam turbine.

• Air tank/Air reservoir: This is a MS cylinder (popularly known as pressure vessel) similar to
domestic gas cylinder. This tank stores compressed air which is output of air compressors.
Con…
• Moisture separator: Air contains particles of water called 'moisture'. These very fine particles of water must be removed from air
otherwise, if they flow along with air, then they can rust the metal parts in system. 'Water trap' is a moisture separator. Other
chemical or mechanical separators are also used. In these separators part moisture is separated.

• Air filter – Air pressure regulator – Air Lubricator (F.R.L): This is combined unit available readymade in the market. The air first gets
filtered, then its pressure is regulated and then some fine particles of lubricating oil are mixed with air in lubricator. The particles
help in proper lubrication of sliding parts/rotary parts of actuator and valves.

• Direction control valves/Flow control valves/Other valves (Control of air): These valves direct the flow of air, control the flow of
air to control speed of actuators etc.

• Air actuators: These items are the heart of pneumatic system. Actuators are taking part in obtaining mechanical advantage or you
may say, useful work from compressed air. These are either linear actuators or rotary actuators.

• Air conducting elements: The compressed air flows through pipes (GI pipes/Hoses etc.) There are on-off valves, pressure gages
attached to pipe. All these elements comes under this head.
Air Compressors

• Air compressors are the devices which gives energy to the medium of pneumatic system i.e. Air. The
compressors can be divided in many types. But those can be broadly classified in two groups:

• (a) Positive displacement compressors : This type a definite volume air is compressed. So that the
volume of air reduces and naturally its pressure increases. These compressors are either reciprocating
or rotary type.

• (b) Dynamic compressors or turbo compressors: In this type of compressors, rotating impellers impart
velocity and pressure to the flow of air being handled. If large volume of air with low pressure is
required then dynamic compressors are adopted.
Classification of Compressors
Single Acting Reciprocating
Compressors…
Double Acting Reciprocating Compressors…
Diaphragm
Compressors
Vane
Compressors
Lobe Compressors
Liquid Ring Compressors
Scroll Compressor
Screw Compressors
Centrifugal Flow
Compressors
Air Axial flow
Compressors
Con…
Mixed Flow
Compressors
Air Receiver / Air Storage
• The next component of any pneumatic
circuit after compressor is Air Receiver.
Generally, air compressor and air tank is an
essential pair in any pneumatic circuit. The
main functions of air receiver are:
• It provides reserve storage of compressed air.
• It smoothens out the pulsation in flow from
reciprocating machine.
• It helps to cool the warm compressed air.
• It helps to condense the moisture in air.
Schematic
Diagram,
Construction
of Air Receiver
Con…
Merits of Pneumatic Systems
• The working medium of pneumatic system is air, which is easily and freely available.

• Air is dry and hence any pneumatic system is clean. (In hydraulics systems the system is not clean due to presence of oil). Due
to this property, pneumatic circuits are most widely used in the food industry automation and electronic industry automation.

• Air cannot be exploded. (In hydraulic systems, if the temperature of system goes beyond the flash point of hydraulic oil then
there is possibility of fire). Hence pneumatic circuits can be easily used in fire prone area.

• The equipment used in pneumatic systems are easy in working and easy in manufacturing.

• The pneumatic equipment such as chipper, grinders, rotary actuators, linear actuators, are having comparatively low cost and
are light weight.

• The maintenance cost of pneumatic equipment and circuit elements like compressors, FRL unit, DC valves, actuators etc. is
low.
Con…

• Pneumatic systems are not having return lines. Hence, the total cost of system is low.

• Return lines: In hydraulic systems, the medium i.e. oil is pressurized and then after doing useful work needs to
be return to reservoir of soil. So we need special piping for flow of returning oil from actuators. These pipelines
are known as return lines. In pneumatic systems, the compressed air after doing useful work in actuator, is
exhausted to atmosphere. It need not to be returned.

• Compressed air can be transported through light weight pipes.

• The compressed air can be stored in Air tank under pressure. When air tank is full, the air can be used as and
when required. During this period compressor is switched-off, which saves electric power (In hydraulic system,
to pressurize oil we have to run the hydraulic pump continuously).
Limitations of Pneumatic Systems

• Pneumatic system can be used up to 10 bar pressure. If the circuit requires pressure below 10 bar (10 kg/cm2)
then we can use pneumatic circuit. But if the circuit requires pressure more than 10 bar we have to go with
Hydraulic circuit. The Hydraulic circuit can operate up to 700 bar pressure. This is the main limitation of
pneumatic systems.

• If the pressure of stored air in air tank drops below required pressure, then pneumatic circuit stops working. It
will start only after, required pressure is developed in air tank.

• Due to compressing nature of air, accurate motions in actuator are not possible to obtain.

• In CNC/VMC machines, the tool movements needs to be very accurate. This accuracy can be in order of
plus/minus 10 microns. This cannot be achievable in pneumatic circuits. So, in VMC/CNC machines, hydraulic
circuits are used for tool movements.
Applications
of
Pneumatic
Systems
Con…