1.

Co-ordinated motion of multiple pneumatic actuators in a desired sequence using cascade method
Pre-requisites:
Basics of Pneumatics, sequential circuit design by cascade method
Pneumatic valves and other components

1.1.0 Objective:
To design a pneumatic sequential circuit using cascade method, for the given industrial application that involves co-ordinated motion
of multiple actuators.

1.1.1 Problem definition:

Grooves are to be cut in wooden frames on a shaper (Fig 1.1). The wooden frame is to be clamped with a pneumatic cylinder-A as
shown in Fig 1.1. The feed of the shaper table is carried out by a pneumatic feed unit (cylinder-B). After the groove is cut, the shaper
table retracts back, followed by unclamping. Design a sequential logic circuit for the above sequence of operations using cascade
method. The cycle has to start only if a start button is pressed by an operator.

Wooden frame
Clamping cylinder-A
Groove
Cutter a0

Shaper table a1

b1 b0 Feed cylinder-B

Fig 1.1 Groove cutting using a shaper

1.1.2 Identification of the sequence:

Various steps involved in the above sequential operation are listed below:

The wooden frame has to be clamped first, which is achieved through the extension of clamping cylinder-A. Hence, the first
step of the sequence is extension of cylinder-A, i.e. A1. (The letter „1‟ represents forward movement of an actuator)

Once clamped, the wooden frame has to be fed towards the cutter by extension of feed unit (cylinder-B) along with the shaper
table and thus cutting a groove in the wooden frame. Hence, the second step of the sequence is extension of cylinder-B,
i.e. B1 (It is assumed that the cutter is rotating).
Once the groove is cut, the shaper table has to retract, which is achieved by retraction of the feed unit (cylinder-B). Hence, the
third step of the sequence is retraction of cylinder-B, i.e. B0. (The letter „0‟ represents retraction of an actuator)
Unclamping of the wooden frame is achieved through retraction of cylinder-A. Hence, the next step of the sequence is
retraction of cylinder-A i.e. A0.
So, the appropriate sequence for the above application is A1 B1 B0 A0.

The cycle has to start, only if a start button is pressed by an operator and hence, a start button is introduced at the beginning
(i.e., between the last and first steps) of the sequence (i.e. start A1 B1 B0 A0 - start A1 B1 B0 A0…)
1.1.3 Traverse step diagram:

Traverse step diagram is a graphical representation of the sequence of operations.

The current sequence involves two cylinders A and B (actuators). Hence, the traverse step diagram will have two blocks, one
each for an actuator.

Fig 1.2 Cylinder – A with limit switches ‘a0’ and ‘a1’

a0 and a1 correspond to the home position and extended position of the cylinder-A as shown in Fig 1.2; in addition, limit
switches are placed at positions a0 and a1 to keep track of the end positions occupied by the cylinder-A respectively.
Conventionally, limit switches located at a0 and a1 are designated as limit switches a0 and a1 respectively.

The details of the traverse step diagram are illustrated in Fig 1.3. The figure pictorially depicts the two different blocks, one
each for cylinders A and B, the limit switch configurations, the forward and return strokes of the actuators as per the sequence.
The different columns represent activities, not drawn to time scale.
 Block for cylinder – A
cylinder-A remaining in extended position A
column-1 column-2 column-3 column-4 a1

a1
Forward stroke of cylinder-A Return stroke of cylinder-A
(i.e. a line with the positive slope) (i.e. a line with the negative slope)
A

a0
Block for cylinder-B

b1 Return stroke of cylinder-B

Forward stroke of cylinder-B
B
cylinder-B remaining in home The listed items denote the appropriate control
position B b0 action to be triggered for various configuration of
A1 B1 B0 A0 the system. eg. A1, forward movement of the
b0
cylinder - A is to be triggered when the cylinder-A
is at a0 position and cylinder-B is at b0 position
a0 a1 a1 a1 a0
Configuration of the system as defined by
b0 b0 b1 b0 b0 the limit switches pressed by the actuator

Fig 1.3 Traverse step diagram for the sequence A1 B1 B0 A0

1.1.4 Grouping of sequence by cascade method:
The identified sequence for the above industrial application is A1 B1 B0 A0, which is going to repeat each time for a
component, once a wooden frame is loaded.

In cascade method, the sequence is grouped in such a way that the forward and return strokes of any cylinder do not fall in one
group, so that this signal clash problem can be avoided. Fighting signal is a conflicting situation when an actuator is
commanded to perform both forward and return strokes simultaneously.

Such a fighting signal situation arises if both the pilot lines that activate the forward and return of an actuator through a
direction control valve of the actuator receive the input signals simultaneously.

The sequence can be divided into two groups, I and II as follows,

A1 B1 B0 A0
I II
thick line - 1 thick line - 2

It can be seen that if independent pressure lines are assigned to groups I and II, and only one of them is alive at a given time
(i.e. carry pneumatic pressure), the signal clash can be avoided. The thick line separating the two groups, calls for a group
change action i.e. the thick line - 1 calls for a change of group from I to II making the group II pressure line active, thick line -
2 will return the pneumatic pressure from group II to I. Initially it can be visualized that the pressure is available in group I i.e.
group I pressure line is alive.

The group change can be achieved by actuating a Group change valve (GCV), which is basically a 5/2 pilot operated valve.
Number of Group change valves (GCV) = No. of groups – 1
= 2-1
=1

The pressure lines corresponding to the two groups are designated as „GI‟ and „GII‟ and they are made alive by appropriately
actuating the GCV. At any instant, either „GI‟ or „GII‟ will be alive.
1.2.0 Pneumatic circuit diagram:

The pneumatic circuit diagram for the sequence outlined in the previous section is shown below in Fig 1.4

Cylinder-A 2 1 2 Cylinder-B 1 2 1 2
1

3 a0 3 a1 3 b0 3 b1
4 2 4 2

14 12 14 12

DCV-A 5 1 3
DCV-B 5 1 3

GII

GI
2 4 2

14 12

Start button 1 3 5 1 3
GCV

FRL unit

Fig 1.4 Pneumatic circuit diagram for the sequence A1 B1 B0 A0.

It can be seen that the pneumatic circuit shown in Fig 1.4, (the symbols are drawn as per ISO standard 1219) has the following
features:

Two cylinders A and B serve as actuators for the sequence, these cylinders are double acting cylinders as indicated by their
symbols.

The symbol for the cylinder is as follows:

Each cylinder has two limit switches (pneumatic type) to monitor the end positions of that cylinder i.e. limit switches a0 and a1
for cylinder – A, and limit switches b0 and b1 for cylinder - B as indicated in Fig 1.4.

The symbol for the limit switches is

2

1 3

The forward and retraction strokes of cylinders A and B are initiated by their respective pilot operated 5/2 direct control
valves, DCV - A and DCV – B (5 represents the number of ports and 2 represents the number of positions of the DCV). Port1,
in the DCV corresponds to pressure port; ports 2 and 4 are working ports connected to the ports of actuators; ports 3 and 5 are
termed as exhaust ports connected to silencer/atmosphere.

A typical 5/2 DCV is denoted as

4 2

14 12
51 3
 Ports 14 and 12 of the DCV are the pilot ports, which when triggered, will perform respectively the forward and return strokes
of the actuator.

There is a group change valve (GCV) at the bottom of the circuit which is also another 5/2 pilot operated direction control
valve; Its output will be connected to the two pressure lines GI and GII as the number of groups is 2 as per the cascade method.
The input to all the pressure ports, i.e., the pressure ports of DCV - A, DCV - B and GCV will be from an FRL unit as shown
in Fig 1.4.

The symbol for GCV is also the same as that of DCV. The simplified representation of FRL unit is

A start button which sets the sequence of operation into action is connected to the pressure lines GI; The start button is a 3/2
direction control valve where output port 2 initiates the first activity in the sequence i.e. operation A1 by activating the pilot
port 14 of DCV- A.
2
The standard symbol of the start button is

1 3
The input limit switches a0, a1, b0 and b1 (they are also 3/2 DCVs) are connected to the current live power line as per cascade
method; their output will trigger the following activity of the sequence (or effect a group change by triggering the pilot control
of GCV).

Fig 1.4 depicts the appropriate inter - connection between the actuators, DCVs, the limit switches, the GCV, pressure lines GI
and GII for the sequence under consideration as per cascade method.

The above connections are to be made systematically as outlined in the following section in order to realise the sequence under
consideration.
1.3.0. Component List:

Based on the circuit discussed in the previous section, a list of components required to be used for the realization of the pneumatic
system is provided below:

[Link] Item Quantity

1. Double acting cylinder [Fig.1.5] 2

2. Limit switch (3/2 roller operated spring return direction control valve) [Fig.1.6] 4

3. Directional control valve (5/2 double pilot operated direction control valve) [Fig.1.7] 2

4. Group change valve (5/2 double pilot operated direction control valve) [Fig.1.8] 1

5. Start button (3/2 push button operated spring return direction control valve) [Fig.1.9] 1

6. T- connectors [Fig.1.10] 4

7. Connector tubes (PU 4) [Fig.1.11] As required

The above list of components is in addition to the standard work table where the pneumatic components will be fixed and the FRL unit
which provides a regulated air supply at approximately 6 bar pressure after fabrication and addition of traces of lubricant for the
relatively moving parts in the system. The technical specification for the components listed above is given in the following sections.
1.3.1 Double acting cylinder - 2 numbers
(One each for cylinder - A and cylinder- B)

Rod end
Specification:
Piston end 1. Stroke 100 mm
2. Piston diameter 20 mm
3. Piston rod thread M8
4. Piston rod end Male thread
5. Operating pressure 1 to 10 bar
6. Conforms to standard CETOPRP52P ISO 6432
7. Mode of operation Double-acting
8. Ambient temperature -20 to 80°C
9. Pneumatic connection G 1/8
Fig 1.5 Double acting cylinder 10. Material for piston rod, High alloy steel, non-
cylindrical barrel corrosive

1.3.2 Limit switch (3/2 roller operated spring return direction control valve) - 4 numbers
(Two limit switches for each double acting cylinder- one to confirm the extended position and the other to confirm the retracted
position of the cylinder)

Port 2
Specification:
1. Valve function 3/2 normally
closed
Port 1 2. Type of actuation mechanical
3. Nominal flow rate 80 lpm
4. Operating pressure -0.95 to 8 bar
5. Nominal size 2 mm
6. Ambient temperature -10 to 60°C
7. Pneumatic connection ports 1,2 M5
8. Housing material Zinc die casting
Fig 1.6 Limit switch
1.3.3 Directional control valve (5/2 double pilot operated direction control valve) - 2 numbers
(One directional control valve for each double acting cylinder to shift to extension and retraction strokes)

Specification:
Port 4 Port 2 1 Valve function 5/2
2 Std nominal flow rate 600 lpm
3 Operating pressure -0.95 to 10 bar
4 Nominal size 5 mm
Port 1 Port 12
5 Pilot pressure 1 to 10 bar
Port 14
6 Switching time reversal 2 ms
7 Port size (all ports) G 1/8
8 Housing material Aluminum die casting

Fig 1.7 Directional control valve

1.3.4 Group change valve (5/2 double pilot operated direction control valve) - 1 number
(One GCV to shift to either „GI‟ or „GII‟ pressure line; specification is same as that of DCVs listed in previous section)

Port 4 Port 2

Port 14 Port 1 Port 12

Fig 1.8 Group change valve

1.3.5 Start button (3/2 push button operated spring return direction control valve) – 1 no
(to start a new cycle)
Port 1
Specification:
1. Valve function 3/2 closed
Port 2 2. Type of actuation Manual
3. Nominal flow rate 80 lpm
4. Operating pressure -0.95 to 8 bar
5. Nominal size 2 mm
6. Ambient temperature -10 to 60°C
7. Pneumatic connection ports 1,2 M5
8. Housing material Zinc die casting

Fig 1.9 Start button

1.3.6 T –connectors - 4 numbers

(to connect the tubes to appropriate device ports from „GI‟ and „GII‟ pressure lines)

Specification:
1 Outer diameter 6 mm
2 Inner diameter 4 mm
3 Design structure Push/pull principle
Temperature dependent
4 -0,95 ... 14 bar
operating pressure
Compressed air in accordance
5 Operating medium
with ISO8573-1:2010 [7:-:-]
6 Number of outputs 2
Fig 1.10 T –connectors 7 Number of supply lines 1
1.3.7 Connector tubes (PU 4)
(to supply air to devices)
Specification:
1 Outer diameter 4 mm
2 Inner diameter 2.6 mm
3 Minimum bending radius 8 mm
4 Operating pressure -0.95 to 10 bar
5 Materials note Free of copper and
PTFE
6 Material for tubing TPE-U(PU)

Fig 1.11 Connector tubes

The T-connectors facilitate branching off from one line to two other lines, whereas the connector tubes allow extension of pneumatic
tubes to meet the space constraints of various elements in the pneumatic system. The size of all the tubes employed is 4 mm,
designated as, PU 4, a standard plastic tube made of poly urethane.
1.4.0 Step-by-step Procedure:

In this section, a detailed step by step procedure for the synthesis of pneumatic hardware in order to realise the pneumatic sequence is
shown figuratively. In each step an incremental addition of a feature is made for clarity of the reader.

All the pneumatic elements will be fixed on to the standard work table where the simulation of the pneumatic sequence could be seen
by the users. The pneumatic work table arrangement is shown in Fig 1.12 (a) which is a back-to-back arrangement, designed
ergonomically to permit two groups of students to assemble the pneumatic components firmly on either side for hands-on-training.

Fig 1.12 (b) clearly shows the cylinder connecting piece and pneumatic work table slot arrangement.

Fig.1.12 (a) – Pneumatic work table

 Knob

Step-1: Connecting piece is inserted

in the slot

Connecting piece

Step-2: Knob is rotated in CW

direction (therefore, connecting piece
moves towards the profile plate)

Slot Step-3: Knob is further rotated in

CW direction (therefore, connecting
piece holds the profile plate)
Knob

Worktable

Fig.1.12 (b) – Mounting arrangement of pneumatic components onto the work table
1. The two double acting cylinders (A and B) are fixed on the table as shown in Fig 1.13. (PE – Piston end; RE – Rod end)
2. Air Manifold: For distribution of compressed air through several input ports in the system (i.e. from 2 Inlets to 6 outlet
connections) for easy tube connection.
Air Manifold

PE RE PE RE

Cylinder-A Cylinder-B

Fig 1.13 Step-1 of the pneumatic sequence A1 B1 B0 A0

3. Two limit switches are fixed for cylinder-A to confirm its extended and retracted positions, as shown in Fig 1.14. The limit
switches used to confirm the retracted and extended positions are designated as „a0‟ and „a1‟ respectively as indicated in the
previous section. Similarly, two limit switches „b0‟ and „b1‟ are fixed for cylinder-B, as shown in Fig 1.14.

PE RE PE RE

2 2 2 2
Cylinder-A Cylinder-B
1 1 1 1

b0 b1
a0 a1

Fig 1.14 Step-2 of the pneumatic sequence A1 B1 B0 A0

4. Two 5/2 way double pilot operated direction control valves (DCVs), DCV-A and DCV-B for actuating the cylinders A and B
respectively are mounted on the table, as shown in Fig 1.15.

PE RE PE RE

2 2 2 2
Cylinder-A Cylinder-B
1 1 1 1

a1 b0 b1
a0

4 2 4 2
12 12
14 14
1 1
DCV-A DCV-B

Fig 1.15 Step-3 of the pneumatic sequence A1 B1 B0 A0

5. A 5/2 way double pilot operated DCV, which is termed as group change valve (GCV) for shifting the pneumatic pressure
between the pressure lines of groups I and II is fixed on the table, as shown in Fig 1.16.

PE RE PE RE

2 2 2
2 Cylinder-B
Cylinder-A
1 1 1
1

a0 a1 b0 b1

4 2 4 2
14 12 14 12
1 1
DCV-A DCV-B

14 4 2
12
1
GCV

Fig 1.16 Step-4 of the pneumatic sequence A1 B1 B0 A0

6. A START button, which is a 3/2 push button operated spring return valve is fixed adjacent to the GCV, as shown in Fig 1.17.

PE RE PE RE

2 2 2 2
Cylinder-B
Cylinder-A 1
1 1
1

a0 a1 b0 b1

4 2 4 2
12 14 12
14
1 1
DCV-A DCV-B

4 2
2 12
14
START button 1
GCV

Fig 1.17 Step-5 of the pneumatic sequence A1 B1 B0 A0

7. „Port 4‟ of the DCV-A, a working port, is connected to the piston end side (PE) of cylinder-A, as shown in Fig 1.18. The
dotted line shows the tube connection to be effected.

PE RE PE RE

2 2 2 2
Cylinder-A
Cylinder-B
1 1 1 1
a0 a1 b1
b0

4 2 4 2
12
14 12
1 14 1

DCV-A
DCV-B

1
4 2
2 4 2 12
14 GCV
14 1
START button
1

Fig 1.18 Step-6 of the pneumatic sequence A1 B1 B0 A0

8. „Port 2‟ of the DCV-A, the other working port, is connected to the rod end side (RE) of cylinder-A, as shown in Fig 1.19.

PE RE PE RE
2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1
a0 a1 b1
b0

4 2 4 2
12
14 12
1 14 1

DCV-A
DCV-B

4 2
2 12
14 GCV
START button 1

Fig 1.19 Step-7 of the pneumatic sequence A1 B1 B0 A0

9. Similar procedure is adopted in connecting the ports 4 and 2 of the DCV-B to the piston and rod ends of the cylinder-B
respectively, as shown in Fig 1.20.

PE RE PE RE

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1
a0 a1 b1
b0

4 2 4 2
12
14
1 14 1 12

DCV-A
DCV-B

4 2
2 12
14 GCV
START button 1

Fig 1.20 Step-8 of the pneumatic sequence A1 B1 B0 A0

10. „Port 1‟ of both the DCVs and the GCV are connected to the pressure line, which is the output from a compressor supplying
compressed air through an FRL unit discussed previously, as shown in Fig 1.21.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1
a0 a1 b1
b0

4 2 4 2
12
14 1 12
14
1

DCV-A
DCV-B

2 4 2
12
14 GCV
START button 1

Fig 1.21 Step-9 of the pneumatic sequence A1 B1 B0 A0

1.4.1 Group-I Connections:
1. The output from „port 4‟ of the GCV is taken and is connected to „port 1‟ of the START button, using T-joint, as shown in
Fig 1.22.

2 2 2 2
Cylinder-A
1 1 Cylinder-B 1 1

a0 a1 b1
b0

4 2 4 2
14 1
1 14 12
2
1

DCV-A
DCV-B

GI
2 4 2
12
14
GCV
START button 1

Fig 1.22 Step-1 of group I connection

2. The output from „port 4‟ of the GCV is taken and is connected to „port 1‟ of the limit switches a1 and b1, using T-joint, as
shown in Fig 1.23.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
12
14 1
14 12
1

DCV-A
DCV-B

1
GI
4 2
2 12
14 GCV
START button 1

Fig 1.23 Step-2 of group I connection

3. „Port 2‟ of the START button is connected to the „pilot port 14‟ of the DCV-A, as shown in Fig 1.24.

2 2 2 2
Cylinder-A
1 1 Cylinder-B 1 1

a0 a1 b1
b0

4 2 4 2
12
14 1 14 12
1

DCV-A
DCV-B

1
GI
2 4 2
12
14 GCV
START button 1

Fig 1.24 Step-3 of group I connection

4. „Port 2‟ of the limit switch „a1‟ is connected to the „pilot port 14‟ of the DCV-B, as shown in Fig 1.25.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
12
14 1 12
14
1

DCV-A
DCV-B

1
GI
2 4 2
12
14 GCV
START button 1

Fig 1.25 Step-4 of group I connection

5. „Port 2‟ of the limit switch „b1‟ is connected to the „pilot port 12‟ of the GCV, as shown in Fig 1.26.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
12
14 1 14 12
1

DCV-A
DCV-B

1
GI
2 4 2
12
14 GCV
START button 1

Fig 1.26 Step-5 of group I connection

1.4.2 Group-II connections
1. „Port 2‟ of the group change valve is connected to „pilot port 12‟ of the DCV-B using T-joint, as shown in Fig 1.27.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1
a0 a1 b1
b0

4 2 4 2
14 12 12
1 14
1

DCV-A
DCV-B

1 GII
GI
2 4 2
12
14 GCV
START button 1

Fig 1.27 Step-1 of group II connection

2. „Port 2‟ of the group change valve is connected to „port 1‟ of the limit switches „a0‟ and „b0‟ using T-joint, as shown in
Fig 1.28.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
14 12 12
1 14
1

DCV-A
DCV-B

1 GII
GI
4 2
2 12
14 GCV
START button 1

Fig 1.28 Step-2 of group II connection

3. „Port 2‟ of the limit switch „b0‟ is connected to the „pilot port 12‟ of the DCV-A, as shown in Fig 1.29.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
14 1 12 14 12
1

DCV-A
DCV-B

1 GII
GI
2 4 2
12
14 GCV
START button 1

Fig 1.29 Step-3 of group II connection

4. „Port 2‟ of the limit switch „a0‟ is connected to the „pilot port 14‟ of the GCV, as shown in Fig 1.30.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
14 1 12 14 12
1

DCV-A
DCV-B

1 GII
GI
4 2
2 12
14 GCV
START button 1

Fig 1.30 Step-4 of group II connection

5. The connected system for the sequence A1 B1 B0 A0 is shown in Fig 1.31.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
14 1 12 14 12
1

DCV-A
DCV-B

1 GII

GI
4 2
2 12
14 GCV
START button 1

Fig 1.31 Step-5 of group II connection

1.4.3 Working of the pneumatic circuit:
1. The cylinders A and B are in the retracted position initially and hence, the limit switches „a0‟ and „b0‟ are pressed.
2. Since the „port 2‟ of limit switch a0 is connected to „pilot port 14‟ of the GCV, Group I is energised, as shown in Fig 1.32.
3. The currently active lines i.e. lines with pressurised air supply are shown in dashed line.

2 2 2 2
Cylinder-A
1 1 Cylinder-B 1 1
a0 a1 b1
b0

4 2 4 2
14 1 12 14 12
1

DCV-A DCV-B

GII
1
GI
4 2
2 12
14 GCV
START button 1

Fig 1.32 Working of circuit -1

4. The air supply from the GCV „port 4‟ enters the START button, as shown in Fig 1.33.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
14 1 12 14 12
1

DCV-A
DCV-B

GII
1
GI
4 2
2 12
14 GCV
START button 1

Fig 1.33 Working of circuit -2

5. Once the START button is pressed, „pilot port 14‟ of the DCV-A receives signal, thereby extending cylinder-A, as shown in
Fig 1.34.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
14 1 12 14 12
1

DCV-A
DCV-B

1 GII
GI
4 2
2 12
14 GCV
START button 1

Fig 1.34 Working of circuit -3

 6. Once, cylinder-A fully extends, it presses the limit switch „a1‟, as shown in Fig 1.35.

PE RE PE RE

2 2 2 2
Cylinder-A 1 Cylinder-B
1 1 1

a0 a1 b0 b1

4 2 4 2
14 12 12
14 1
1
DCV-A DCV-B
START button
1 GII
GI
2 4 2
12
14

GCV 1

Fig 1.35 Working of circuit -4

7. Since „port 2‟ of the limit switch „a1‟ is connected to the „pilot port 14‟ of the DCV-B, cylinder-B extends, as shown in
Fig 1.36.

PE RE PE RE

2 2 2 2
Cylinder-A 1 Cylinder-B
1 1 1

a0 a1 b0 b1

4 2 4 2
14 12 12
14 1
1
DCV-A DCV-B
START
button 1 GII
GI
2 4 2
12
14
GCV 1

Fig 1.36 Working of circuit -5

8. Once, cylinder-B fully extends, it presses limit switch „b1‟, as shown in Fig 1.37.

PE RE PE RE

2 2 2 2
Cylinder-A Cylinder-B
1 1 1
1

a0 a1 b0 b1

4 2 4 2
14 12 12
14 1
1
DCV-A DCV-B
START button

1 GII

GI
4 2
2 14 12
1
GCV

Fig 1.37 Working of circuit -6

9. Since, „port 2‟ of the limit switch „b1‟ is connected to the „pilot port 12‟ of the GCV, now Group-II gets energised, as shown in
Fig 1.38.

PE RE PE RE

2 2 2 2
Cylinder-A Cylinder-B
1 1 1
1

a0 a1 b0 b1

4 2 4 2
14 12 12
14 1
1
DCV-A DCV-B
START button
GII
1
GI
4 2
2 14 12
1
GCV

Fig 1.38 Working of circuit -7

10. The air supply from GCV „port 2‟ sends signal to pilot „port 12‟ of the DCV-B, thereby retracting cylinder-B, , as shown in Fig
1.39.

PE RE PE RE

2 2 2 2
Cylinder-A Cylinder-B
1 1 1
1

a0 a1 b0 b1

4 2 4 2
14 12 12
14 1
1
DCV-A DCV-B
START button
GII
1
GI
4 2
2 14 12
1
GCV

Fig 1.39 Working of circuit -8

11. Once, cylinder-B fully retracts, it presses the limit switch „b0‟, as shown in Fig 1.40.

PE RE PE RE

2 2 2 2
Cylinder-A 1 Cylinder-B
1 1 1

a0 a1 b0 b1

4 2 4 2
14 12 12
14 1
1
DCV-A DCV-B
START button
1 GII
GI
2 4 2
12
14

GCV 1

Fig 1.40 Working of circuit -9

12. Since, „port 2‟ of the limit switch „b0‟ is connected to the pilot „port 12‟ of the DCV-A, cylinder-A retracts, as shown in
Fig 1.41.

PE RE PE RE

2 2 2 2
Cylinder-A 1 Cylinder-B
1 1 1

a0 a1 b0 b1

4 2 4 2
14 12 12
14 1
1
DCV-A DCV-B
START button
1 GII
GI

2 4 2
12
14

GCV 1

Fig 1.41 Working of circuit -10

13. Once cylinder-A fully retracts, it presses the limit switch „a0‟, as shown in Fig 1.42.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
14 1 12 14 12
1

DCV-A
DCV-B

1 GII
GI
4 2
2 12
14 GCV
START button 1

Fig 1.42 Working of circuit -11

14. Since the „port 2‟ of limit switch „a0‟ is connected to pilot „port 14‟ of the GCV, Group I is energized, , as shown in Fig 1.43.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
14 1 12 14 12
1

DCV-A
DCV-B

1 GII
GI
4 2
2 12
14 GCV
START button 1

Fig 1.43 Working of circuit -12

15. The air supply from the GCV „port 4‟ enters the START button.

16. Again, the cycle starts once the START button is pressed, as shown in Fig 1.44.

2 2 2 2
Cylinder-A
1 1 Cylinder-B
1 1

a0 a1 b1
b0

4 2 4 2
14 1 12 14 12
1

DCV-A
DCV-B

1 GII
GI
4 2
2 12
14 GCV
START button 1

Fig 1.44 Working of circuit -13

1.4.4 Conclusion:

Thus, the appropriate hardware elements were fixed, tubing connections were made and the designed sequential circuit was
experimentally validated to meet the functional requirement of the specified sequence A1 B1 B0 A0.

1.5.0 Simulation of the sequence of operation:

Video
1.6.0 Frequently asked questions:

1. How can the speed of the cylinder be controlled?

The speed of the cylinder can be controlled using flow control valves.

2. Where can I control the pressure supply to the pneumatic system?

The pressure of air to the system can be controlled in the FRL unit.
3. Why is it necessary to ensure proper insertion of tubes into the ports?

If the tube is not inserted properly into the ports, due to pressure of air, it comes out of the port and wobbles at a faster rate.
This may hit the eyes or parts of the body. So, ensuring proper insertion of tubes into the ports is necessary.

4. „Some times, even after connecting the hardware as per the circuit diagram, the circuit won‟t work. During such times, it is
recommended to cut off the air supply before debugging the circuit‟ – why?

If there are loose connections, the circuit won‟t work. If we try to modify it before cutting off the air supply, there is a chance
that suddenly the devices may work and the actuation of cylinder (and thereby the cam attached at its end) might hit our hands
or body.

5. Pneumatic components are generally designed for a maximum operating pressure of 8 to10 bar

6. It is desirable to minimize the number of groups, while grouping the sequence as per cascade method – Justify.
Number of group change valves = Number of groups – 1
If number of groups increase, the number of group change valves also increase. This leads to increase in number of
components and cost of the system.

7. For the under mentioned sequence, determine the number of groups by cascade method and show the connections among the
group change valves.
Sequence: A1 B1 B0 C1 C0 A0
For the given sequence, grouping is done as follows using cascade method.

A1 B1 B0 C1 C0 A0

I II III
Number of group change valves = 3-1 = 2

GI
GII
GIII

GI GII GII GIII

8. If a continuous cycle is desired without interruption, suggest the change(s) in the circuit studied.
 The start button (3/2 push button operated spring return valve) can be removed from the studied circuit, so that the
cycle is continuous without interruption.

9. Why is a cam arrangement provided at the front end of piston rod?

A cam arrangement is provided at the rod end of the cylinder so that it can confirm its position (extension or
retraction) by pressing the roller of the appropriate limit switch.
 1.7.0 Self assessment questions:

1. Identify the number of groups for the sequence A1 B1 B0 C1 D1 D0 C0 A0, as per cascade method.
2. Identify the following pneumatic components

a) b) c)

3. Valve bodies are to be marked with the letters „PSG‟. The valve bodies are placed in the holder manually. Stamping cylinder (A)
stamps the letters in the body. Cylinder B pushes the parts from the holder into a basket. Write down the sequence code for it. The
arrangement is shown in the figure given below.
Cylinder-A

Cylinder-B
Sequence code: __________________
Bin

4. Identify the valve shown in the figure below and designate the given valve using port numbers as per ISO 5599-3 standard

/n way valve
14
 5. What is positive displacement compressor?
6. Why is a lubricator used in pneumatic system?
7. Draw the traverse step diagram for the sequences A1 B1 C1 C0 B0 A0 and A1 A0 B1 B0.

1.7.1 Solution for Self assessment questions:

1. Three groups
2. a) 5/3 direction control valve, b) One way flow control valve (or) Uni-directional flow control valve
c) Two pressure valve (or) AND valve

3. Sequence code: A1A0B1B0

4.
4 2
n way valve
14 Double pilot operated manual over
12
drive 5/2 direction control valve
3 1 5

The configurable 5/n way valve is a way valve with five connections, where both
its body elements and its operation modes are user-definable.
5. Positive displacement pumps supply a fixed amount of compressed air for each cycle. They are capable of supplying air at very
Additionally, the pneumatic connections can be closed with either blind plugs or
high pressures. exhausts.
E.g., reciprocating compressors
6. Lubricator helps Adjustable
in proper parameters
lubrication of internal moving parts in a pneumatic system. If lubricator is not available, dry air enters
Standard nominal flow rate: 0.1 ... 5000 l/min (60)
between the moving parts resulting in more friction between them and thereby more heat generation and premature fail of
components.
7. A1B1C1C0B0A0:

a1
A
a0

b1
B
b0

c1
C
c0
A1 B1 C1 C0 B0 A0

A1A0B1B0:
a1
A
a0

b1
B
b0
A1 A0 B1 B0
1.8.0 Problems / Assignments:

1. The required cycle time of a double acting cylinder is 80 cycles/min. Its bore and rod diameter are 40 mm and 20 mm respectively.
Its stroke length is 120 mm. The supply pressure is 5 bar. Ignore the effects of friction and back pressure. Calculate the following:
a) Extension force
b) Retraction force
c) Air consumption rate
d) Forward speed
e) Retraction speed
f) Forward travel time
g) Return travel time.
2. Develop a double acting pneumatic cylinder circuit such that the flow is controlled in the piston end during extension and flow is
controlled in the rod end during retraction.
1.8.1 Solution for Problems/ Assignments:

1. Given data:
Cycle time, n = 80 cycles / min
Bore diameter, Dp = 40 mm
Rod diameter, Dr = 20 mm
Stroke length = 20 mm
Pressure, P = 5 bar
To find:
i) Extension force
ii) Retraction force
iii) Air consumption rate
iv) Forward speed
v) Retraction speed
vi) Forward Travel time
vii) Return travel time.
Solution:

Extension force: Fext= [Link] = (5x105) x (π/4) x (0.04)2 = 628.32 N

Retraction force: Fret= P.(Ap-Ar) = (5x105) x (π/4) x [(0.04)2-(0.02)2] = 471.24 N

Air Consumption rate: Q= (π/4) x [Dp2 + (Dp2 – Dr2)] x stroke x compression ratio x n

Compression ratio = (1.013+5)/1.013 = 5.9358

 Q= (π/4) [(0.04)2 + {(0.04)2 – (0.02)2}] x 0.12 x 5.9358 x 80 = 0.1253 m3/min

Forward speed: Vext= Q/Ap = [0.1253x (1/60)]/ (π/4) x (0.04)2 = 1.66 m/s

Retraction speed: Vret = Q/Ar = [0.1253x (1/60)]/ (π/4) x [(0.04)2 – (0.02)2] = 2.25 m/s

Forward travel time: text = Stroke length/Forward speed = 0.120/1.66 = 0.0721 s

Return travel time: tret = Stroke length/Return speed = 0.120/2.25 = 0.053 s

2.
1.9.0 Quiz:

1. In 5/3 way directional control valve, 3 denotes

A) No of actions the valve can perform B) No of ports C) No of exhaust ports D) No of positions

2. For the sequence code: A1 B1 C1 C0 B0 D1 A0 D0, the number of group change valves required in pneumatic system design as
per Cascade method will be
A) 3 B) 2 C) 1 D) zero

3. The sequence code: A1 B1 B0 C1 C0 D1 D0 can be divided into _____ number of groups as per Cascade method.
A) 2 B) 3 C) zero D) 4

4. The generally recommended operating pressure in pneumatic systems is

A) 25 bar B) 6 bar C) 40 bar D) 300 bar

5. Which of the following sequential circuit requires two group change valves as per cascade method?
A) A1 B1 C1 A0 B0 C0 B) C1 A1 B0 A0 C0 B1
C) B0 C1 A0 D0 D1 A1 B1 C0 D) D1 B1 B0 D0 A1 A0 C1 C0

1.9.1 Solution for Quiz:

1–D 2- C 3-B 4-B 5-D

1.10.0 Application / Industrial case study:

1. Valve bodies are to be marked with the letters „PSG‟ as shown in Fig 1.45. The valve bodies are placed in the holder manually.
Stamping cylinder (A) stamps the letters in the body. Ejector cylinder (B) pushes the parts from the holder in to a basket. The
positions of the cylinders are confirmed using electrical limit switches. Develop a pneumatic system for the above application
using cascade method. The cycle has to start only if a start button is pressed by an operator.
Cylinder-A

Cylinder-B Holder

Basket

Fig 1.45 Stamping station

2. An automobile industry needs a set-up for bending the sheet metal, as shown in dotted lines in Fig 1.46, using two actuators A and
B. Design a pneumatic circuit for the same using Cascade method.
 Fig 1.45 Bending station

3. A punching press is to be automated in a shop floor. The workpiece is placed in the fixture manually. Then the workpiece is
clamped by a clamping cylinder „C‟. Punching operation is performed by cylinder „P‟. After the punching process is over,
unclamping is done automatically and the operator removes the punched workpiece manually. The cycle has to start only if the
operator presses „START-1‟ and „START-2‟ buttons simultaneously. Develop a pneumatic sequential circuit for the above
application using cascade method.

4. An automated medicine filling station is shown in Fig.1.46. If a push-button is actuated, the dispensing Cylinder-A extends,
thereby opening the feed container and the bottle is filled with medicine. Then, it retracts, closing the feed container and the
separating Cylinder-B retracts and extends again immediately so that a new empty medicine bottle is located under the filling
valve. Develop a pneumatic circuit for the above application using Cascade method.
 Fig 1.46 Medicine filling station

5. A set-up for assembly of component with a base part using a locking pin is shown in Fig 1.47. The component is fixed on the base
part manually. Once the start button is pressed, cylinder „A‟ slowly presses the component into the base part, followed by cylinder
„B‟ which slowly presses the locking pin from the side. After inserting the locking pin, cylinder „B‟ retracts followed by cylinder
„A‟. Develop a pneumatic circuit for the above application using Cascade method.
Fig 1.47 Assembly station
 1.11.0 References:
REFERENCES

1. Peter Rohner, “Fluid Power Logic Circuit Design – Analysis, Design Method and Worked Examples”, Wiley Publications, 1979.
2. Werner Deppert, Kurt Stoll, “Pneumatics in woodworking”, Vogel-Verlag, Wurzburg, 1st edition, 1979.
3. Andrew Parr, “Hydraulics and Pneumatics”, Jaico Publishing House, 1999.
4. Anthony Esposito, “Fluid Power with Applications”, Pearson Education Pvt. Ltd., 5th edition, 2004.
5. Srinivasan R, “Hydraulic and Pneumatic Controls”, Vijay Nicole Imprints Pvt., Ltd., McGraw-Hill Education (India) Pvt. Ltd.,
2nd edition, 2004.
6. The following books by Festo-didactic:
Pneumatic Basic Level TP 101
Advance pneumatic Work Book TP102

Supplementary readings
1. The following books by Festo-didactic:
Closed Loop Pneumatic Work Book TP 111
Cutting Cost with Pneumatics
Clamping with Compressed Air and Vacuum