Advantages of pneumatic systems

o It uses incompressible fluid which results in higher efficiency.

o It delivers consistent power output which is difficult in pneumatic or mechanical

drive systems.

o Hydraulic systems employ high density incompressible fluid.

o Possibility of leakage is less in hydraulic system as compared to that in pneumatic

system.

o The maintenance cost is less.

o These systems perform well in hot environment conditions.

 Cont….
• Material of storage tank, piping, cylinder and piston can be corroded with the hydraulic
fluid.

• Weight and size of the system is more which makes it unsuitable for the smaller
instruments.

• Small impurities in the hydraulic fluid can permanently damage the complete system.

• Leakage of hydraulic fluid is a critical issue and suitable prevention method and seals
must be adopted.

• Hydraulic fluids, if not disposed properly, can be harmful to the environment.

 Cont…
 High effectiveness
• Unlimited supply of air to produce compressed air.
• Not restricted by distance, as it can easily be transported through pipes.
• Compressed air can be released directly into the atmosphere without the need of
processing.

 High durability and reliability

• Pneumatic components are extremely durable and cannot be damaged easily.

 Simple design
• Designs of pneumatic components are relatively simple.
• More suitable for use in automatic control systems.
 Cont…
 High adaptability to harsh environment
• Comparatively compressed air is less affected by high temperature, dust, corrosion,
etc.

 Safety
• Safer because they can work in inflammable environment without causing fire or
explosion.
• Pneumatic components do not burn or get overheated when overloaded.

 Easy selection of speed and pressure

• Speeds of rectilinear and oscillating movement of pneumatic systems are easy to
adjust.
 Cont…
• Pressure and volume of air can easily be adjusted.

• Environmental friendly

• The operation of pneumatic systems do not produce pollutants.

• Pneumatic systems can work in environments that demand high level of cleanliness.

 Economical
• As pneumatic components are not expensive, the costs of pneumatic systems are
quite low.

• Pneumatic systems are very durable, the cost of repair is significantly lower than that
of other systems.
Advantages and distinguishing of compressed air
Cont…
 Limitations of pneumatic systems
 Relatively low accuracy
• As the volume of air may change when compressed or heated, the supply of air to
the system may not be accurate, causing a decrease in the overall accuracy of the
system.

 Low loading
• As the cylinders are not very large, a pneumatic system cannot drive loads that are
too heavy.

 Processing required before use

• Compressed air must be processed before use.
• Moving parts may wear out quickly due to friction.
 Cont…
 Uneven moving speed

• As air can easily be compressed, the moving speeds of the pistons are relatively
uneven.

 Noise

• Noise will be produced when compressed air is released from the pneumatic
components.
Comparison between Systems
Basic components of a hydraulic system
 Cont….
 Functions of the components are as follows:
• The hydraulic actuator is a device used to convert fluid power into mechanical power to
do useful work. The actuator may be of the linear type (cylinder) or rotary type (motor)
to provide linear or rotary motion.

• The hydraulic pump is used to force the fluid from the reservoir to rest of the hydraulic
circuit by converting mechanical energy into hydraulic energy.

• Valves are used to control the direction, pressure and flow rate of a fluid flowing
through the circuit.

• External power supply (motor) is required to drive the pump.

 Cont…
• Reservoir is used to hold the hydraulic oil.

• Piping system carries the hydraulic oil from one place to another.

• Filters are used to remove any foreign particles so as keep the fluid system clean and
efficient, as well as avoid damage to the actuator and valves.

• Pressure regulator regulates the required level of pressure in the hydraulic fluid.

• Cylinder movement is controlled by a three-position change over a control valve.

• When piston of valve is changed to position 3, pressure line is connected to port A
and thus load is raised.
• When position of valve is changed to position 2, pressure line is connected to port B
and thus load is lowered.
 Cont…
• When the valve is at center position 1, it locks the fluid into the cylinder (thereby
holding it in position) and causing all the pump output fluid to return to tank via
pressure relief.
Cont…
Basic components of a pneumatic system
 Cont….
• Air filters: These are used to filter out the contaminants from the air.

• Compressor: Compressed air is generated by using air compressors.

• Air cooler: During compression operation, air temperature increases. Therefore coolers
are used to reduce the temperature of the compressed air.

• Control Valves: Control valves are used to regulate, control and monitor for control of
direction flow, pressure etc.

• Air Actuator: Cylinders and motors are used to obtain the required movements of
mechanical elements of pneumatic system.

• Electric Motor: Transforms electrical energy into mechanical energy. It is used to drive
the compressor.
 Cont…
• Receiver tank: The compressed air coming from the compressor is stored in the air
receiver.
 The functions of various components shown in Fig. are as follows:
• The pneumatic actuator converts the fluid power into mechanical power to perform
useful work.
• The compressor is used to compress the fresh air drawn from the atmosphere.

• The storage reservoir is used to store a given volume of compressed air.

• The valves are used to control the direction, flow rate and pressure of compressed air.

• External power supply (motor) is used to drive the compressor.

• The piping system carries the pressurized air from one location to another.
 Cont….
 Compressed air filter
• It removes all contaminants from the compressed air flowing through it as well as water
which has already condensed.

• Compressed air enters the filter bowl through guide slots.

• Liquid particles are separated centrifugally collecting in the lower part of the filter bowl.

• Collected condensate must be drained regularly otherwise it will mix with the air stream.
 Cont….

Figure :Air filter

 Cont….
 Compressed air regulator
• The purpose of the regulator is to keep the operating pressure of the system virtually
constant regardless of fluctuations in the line pressure and the air consumption.

• High pressure of incoming air is to be reduced.

• When light spring is compressed,

pressure reduction is less.
• If light spring compression is
more, pressure reduction is more.
 Cont….
 Compressed air lubricator
• The purpose of the lubricator is to deliver a metered quantity of oil mist into the air
distribution system when necessary for the operation of the pneumatic system.

Velocity increases as
pressure decreases
 Cont….
• When compressed air passes through throat section its pressure reduces and
lubricant enters in throat.
Cont….
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 Three types of valves are employed in hydraulic systems:
[Link] control valves

[Link] control valves

[Link] control valves

[Link] control valves

• Control the distribution of energy in a fluid power system.

• Provide the direction to the fluid.

• Control the start, stop and change in direction of the fluid flow.

• Contain ports that are external openings for the fluid.

 Cont…
• Number of ports is usually identified by the term ‘way’.

• For example, a valve with four ports is named as four-way valve.

• The fluid flow rate is responsible for the speed of actuator.

DCV can be classified in the following manner:

1) Type of construction:
• Poppet valves
• Spool valves

2) Number of ports:
• Two- way valves
 Cont…
• Three – way valves
• Four- way valves.

3) Number of switching position:

• Two – position

• Three - position

4) Actuating mechanism:

• Manual actuation

• Mechanical actuation

• Solenoid actuation
 Cont…
• Hydraulic actuation

• Pneumatic actuation

• Indirect actuation

 Poppet valve
 Cont….
3/2-way roller lever valve, internal pilot, NC
 Cont….
 How 3/2-way roller lever valve, internal pilot, NC working

o A small hole connects the pressure connection (1) and the pilot valve. If the roller
lever is operated, the pilot valve opens. Compressed air flows to the servo piston and
actuates the main valve disc. First the connection from port (2) to port (3) is closed.
Second the disc seat of the main valve opens, allowing the air to flow from pressure
supply port (1) to working port (2). The air supply for the pilot valve is either internally
connected to the supply port (1) or supplied through a separate port (mostly numbered
12 or 14).
 Cont…
 Spool valve
• Name is derived from their appearance.

• It consists of a shaft sliding in a bore.

• The spool is sealed along the clearance between moving spool and housing (valve body).

• The amount of leakage depends on:

• the amount of clearance

• viscosity of fluid

• the level of the pressure.

• The grooves guide the fluid flow by interconnecting or blocking the holes (ports).
 Cont…
• The spool valves are categorized according to:

• number of operating positions

• the way hydraulic lines interconnections.

• The standard terms are referred as

• Port ‘P’ is pressure port,

• Port ‘T’ is tank port

• Port ‘A’ and Port ‘B’ as working ports.

• The actuators can move in forward or backward direction depending on the connectivity
of the pressure and tank port with the actuators port.
Cont….
 Cont….
2) Number of ports

Two way valves

• Have only two ports

• Also known as on-off valves because they allow the fluid flow only in direction.

• Normally, the valve is closed.

• Available as normally open and normally closed function.

• When actuating force is not applied to the right, the port P is not connected with port A.

• Therefore, the actuation does not take place.

Cont…
 Cont….
 Three way valves
• When a valve has one pressure port, one tank port and one working port

• In this valve, the pressure port pressurizes one port and exhausts another one.

• Only one actuator port is opened at a time.

• In some cases a neutral position is also available when both the ports are blocked.

• Generally, these valves are used to operate single acting cylinders.

Cont…
 Cont…
 Four way valves

• It is generally used to operate the cylinders and fluid motors in both the directions.

• The four ways are: pump port P, tank port T, and two working ports A and B connected to
the actuator.

• The primary function of a four way valve is to pressurize and exhaust two working ports
A and B alternatively.

• When the centered path is actuated, port A and B are

• connected with both the ports P and T respectively.

• In this case, valve is not active because all the ports are open to each other.
 Cont…
• The fluid flows to the tank at atmospheric pressure.

• In this position work cannot be done by any part of the system.

• This configuration helps to prevent heat build up.

 Cont…
• When port B is actuated, the port P is connected with ports B and T is connected with
port A.

• Similarly, when the right end is actuated the port P is connected to A and working port B
is connected to port T.
 Cont…
• The three position valves are used when the actuator is needed to stop or hold at some
intermediate position.

• It can also be used when the multiple circuits or functions are accomplished from one
hydraulic power source.
 Cont…
 According to number/ways of switching position

• Three position valves

• Are used in double-acting cylinders

• Perform advance, hold and return operation to the piston.

• Have three switching positions.

• They have a variety of possible flow path configurations but have identical flow path
configuration.
 Cont…

3) Classification based on actuation mechanism

 Manual actuation
• In this type, the spool is operated manually.

• Manual actuators are hand lever, push button and pedals etc.
 Cont…
 Mechanical actuation

• The DCV spool can be operated by using mechanical elements.

• Roller and cam, roller and plunger and rack and pinion etc.

• Here the spool end is of roller or a pinion gear type.

• The plunger or cam or rack gear is attached to the actuator.

• Thus, the mechanical elements gain some motion relative to the actuator (cylinder piston)
which can be used for the actuation.

 Solenoid actuation

• The solenoid actuation is also known as electrical actuation.

 Cont…
• The energized solenoid coil creates a magnetic force which pulls the armature into the coil.

• This movement of armature controls the spool position.

• The main advantage of solenoid actuation is its less switching time.

 Cont…
 Hydraulic actuation

• This type actuation is usually known as pilot-actuated valve.

• The hydraulic pressure is directly applied on the spool.

• The pilot port is located on one end of the valve.

• Fluid entering from pilot port operates against the piston and forces the spool to move
forward.

• The needle valve is used to control the speed of the actuation

 Cont…

 Pneumatic actuation

• DCV can also be operated by applying compressed air against a piston at either end of
the valve spool.

• The construction of the system is similar to the hydraulic actuation.

 Cont….
• The only difference would be the actuation medium.

• The actuation medium is the compressed air in pneumatic actuation system.

 Indirect actuation of directional control valve

• The direction control valve can be operated by manual, mechanical, solenoidal

(electrical), hydraulic (pilot) and pneumatic actuations.

• The mode of actuation does not have any influence on the basic operation of the
hydraulic circuits.

• Mostly, the direct actuation is restricted to use with smaller valves only because
usually lot of force is not available.
 Cont…
• The availability of limited force is the greatest disadvantage of the direct actuation
systems.

• In practice, the force required to shift the spool is quiet higher.

• Therefore, the larger valves are often indirectly actuated in sequence.

• First, the smaller valve is actuated directly and the flow from the smaller valve is directed
to either side of the larger valve.

• The control fluid can be supplied by the same circuit or by a separate circuit.

• The pilot valve pressure is usually supplied internally.

• These two valves are often incorporated as a single unit.

 Cont…
2 Flow control valve

• Speed of actuator needs to be controlled for desired o/p.

• Actuator speed can be controlled by regulating fluid flow.

• FCV can regulate flow or pressure of fluid.

• Fluid flow is controlled by varying area of the valve opening through which fluid passes.

• Fluid flow can be decreased by reducing the area of the valve opening and it can be
increased by increasing the area of the valve opening. Example to the fluid flow control valve
is the tap.

• The pressure adjustment screw varies the fluid flow area in the pipe to control the discharge
rate.
Cont….
 Cont….
 Types Flow Control Valves

• The flow control valves work on applying a variable restriction in the flow path.

• Based on the construction; there are mainly three types

 Plug valve

Butterfly valve

Ball valve

 Plug or glove valve

• It has a plug which can be adjusted in vertical direction by setting flow adjustment screw.

• Adjustment of plug alters orifice size between plug and valve seat.
 Cont…
• Thus adjustment of plug controls fluid flow in the pipeline.

• The characteristics of these valves can be accurately predetermined by machining the

taper of the plug.

•• The typical example of plug valve is

stopcock that is used in laboratory

glassware.
 Cont…
 Butterfly valve

• It consists of a disc which can rotate inside the pipe.

• The angle of disc determines the restriction.

• Butterfly valve can be made to any size and is widely used to control the flow of gas.

• Butterfly valves are favored because of their lower cost and lighter weight.

• The disc is always present in the flow therefore a drop is induced regardless of the valve
position.
 Cont…

 Ball Valve

• It valve uses a ball rotated inside a machined seat.

• The ball has a through hole as shown in figure.

• It has very less leakage in its shut-off condition.

 Cont…
• Ball valves are durable and work for many years.

• They are excellent choice for shutoff applications.

• They do not offer fine control which may be necessary in throttling applications.

• These valves are widely used in industries because of their versatility, high supporting
pressures (up to 1000 bar) and temperatures (up to 250°C).

• They are easy to repair and operate.

 Cont…

3 Pressure relief valve

• They are used to protect the hydraulic components from excessive pressure.

• This is required for safe operation of the system.

 Cont…
• Its primary function is to limit the system pressure within a specified range.

• It is normally a closed type

• Valve opens when the pressure exceeds a specified maximum value by diverting pump
flow back to the tank.

• Simplest valve contains a poppet held in a seat against the spring force.

• The fluid enters from the opposite side of the poppet.

• When the system pressure exceeds the preset value, the poppet lifts and the fluid is
escaped through the orifice to the storage tank directly.
 Cont…
• It reduces the system pressure and as the pressure reduces to the set limit again the valve
closes.

• This valve does not provide a flat cut-off pressure limit with flow rate because the spring
must be deflected more when the flow rate is higher.
 Cont…
 Compressor:

• It is a mechanical device which converts mechanical energy into fluid energy.

• The compressor increases the air pressure by reducing its volume which also increases the
temperature of the compressed air.

• The compressor is selected based on the pressure it needs to operate and the delivery
volume.

 Piston compressors

• The simplest form is single cylinder compressor.

• It produces one pulse of air per piston stroke.

 Cont…
• As the piston moves down during the inlet stroke the inlet valve opens and air is drawn
into the cylinder.

• As the piston moves up the inlet valve closes and the exhaust valve opens which allows
the air to be expelled.
 Cont…
• Pneumatic components are designed for a maximum operating pressure of 8 - 10 bar. In
practice it operate between 5 and 6 bar for economic use. Due to the pressure losses in
the distribution system the compressor should deliver between 6.5 and 7 bar to attain
these figures.

 The selection of pipe diameter of the air distribution system is governed by:

• Flow rate

• Line length

• Permissible pressure loss

• Operating pressure • Number of flow control points in the line

 Cont….
 Applications of hydraulic systems

Mainly used for precise control of larger forces

 Industrial:

o Plastic processing machineries, steel making and primary metal extraction applications,
automated production lines, machine tool industries, paper industries, textile
machineries, and robotic systems etc.

 Mobile hydraulics:

o Tractors, irrigation system, earthmoving equipment, material handling equipment,

commercial vehicles, tunnel boring equipment, rail equipment, building and construction
machineries and drilling rigs etc.
 Cont…
 Automobiles:

o It is used in the systems like breaks, shock absorbers, steering system, wind shield, lift
and cleaning etc.

 Marine applications:

o It mostly covers ocean going vessels, fishing boats and navel equipment.

 Aerospace equipment:

o There are equipment and systems used for raddar control, flight control and
transmission etc. which are used in airplanes, rockets and spaceships.