AMITY SCHOOL OF ENGINEERING AND TECHNOLOGY DEPARTMENT OF MECHANICAL AND AUTOMATION ENGINEERING

SUBJECT: MECHATRONICS COURSE CODE:- BTM 722 CREDIT UNIT:- 01 LIST OF EXPERIMENTS
Sr. EXPERIMENTS No. 1 2 3 DESIGN AND EXECUTION OF LIFT CONTROL DESIGN AND EXECUTION OF PICK AND PLACE. DESIGN AND EXECUTION OF FAN OPERATION.

4 5 6

DESIGN AND EXECUTION OF WATER LEVEL CONTROL. DESIGN AND EXECUTION OF SEQUENCING SWITCHING MOTORS. DESIGN AND EXECUTION OFSTARTER CONTROL & STAR DELTA FOR HP AC.

7 8

DESIGN AND EXECUTION OF SEVEN SEGMENT DISPLAY MODULE. DIRECT OPERATION OF DOUBLE ACTING

CYLINDER 9 DESIGNING A CIRCUIT FOR SPEED CONTROL OF DOUBLE ACTING CYLINDER METER IN BY EMPLOYING 4/2 DC SOLENOID VALVE.

10

DESIGNING A CIRCUIT FOR SPEED CONTROL OF DOUBLE ACTING CYLINDER METER OUT BY EMPLOYING 4/3 SOLENOID VALVE DESIGNING A CIRCUIT FOR SPEED CONTROL OFHYDRAULIC MOTOR METER IN CIRUIT BY EMPLOYING 4/2 DC VALVE.

11

12

DESIGNING A CIRCUIT FOR SPEED CONTROL OF HYDRAULIC MOTOR METER OUT CIRUIT BY EMPLOYING 4/3 DCVALVE DIRECT ACTING OF HYDRAULIC MOTOR.

13

14

DESIGN A SIMPLE PNEUMATIC DIRECT CONTROL CIRCUIT TO OPEN AND CLOSE THE GATE OF A FACTORY. BY OPERATING A PUSH

BUTTON VALVE, GATE SHOULD OPEN OR CLOSE. 15

DESIGN A PNEUMATIC CIRCUIT USING A DOUBLE ACTING CYLINDER AND 5/2 AIR SPRING VALVE TO OPEN THE MAIN GATE OF A FACTORY WHICH CAN BE CONTROLLED BY A SECURITY PERSONNEL FROM THE SECURITY ROOM.

16

DESIGN A PNEUMATIC CIRCUIT USING A DOUBLE ACTING CYLINDER AND 5/2 AIR SPRING VALVE TO LIFT THE CARTON BOXES AT THE LOADING POINT. THE RAISING AND LOWERING SPEEDS ARE TO BE ADJUSTABLE SEPARATELY.

AJAY SHARMA FACULTY (MECHATRONICS)

EXPERIMENT NO. 1 OBJECTIVE : TO EXECUTE PICK AND PLACE MODULE REFERENCE KIT TO BE USED: PLC TRAINER KIT POSITION INDICATOR CONDITION OF PLKC SWITCH I8 I9 I8 & I9 INPUTS SWITCH LOW COM2 & COM3 COM USED

RIGHT LIMIT SWITCH LEFT LIMIT SWITCH

PICK INDICTAION MOTOR ON

O9 & O4 O8

DESCRIPTION: The pick and place unit has one motor whose direction and switching can be controlled by O8.The right and left limit switch gives signal to change the direction by I8 AND I9.Where as the pick and place is controlled by electro magnet energized, dengerised by O9 and O4 respectively. MOTOR ON O8

PICK INDICTATION O9 AND O4 RIGHT LIMIT SWITCH LEFT LIMIT SWITCH I9 PROCEDURE: EXECUTION FROM EPROM FOR PICK AND PLACE MODULE The following procedure must be carrying out to run the program from EPROM: 1. Press RESET ,B.M. AND 3 2. 2. Press RESET, and then EXEC the program 3. Note that EPROM should be inserted in the ZIF properly keeping PIN No. 1 upper side. RESULT: Execution successful. PRECAUTIONS: 1. DONT TOUCH THE CONTROL PANEL WITHOUT PERMISSION. 2. READ ALL INSTRUCTION BEFORE DOING THE EXPERIMENT. I8

PICK AND PLACE MODULE REFERENCE

EXPERIMENT NO. 2

OBJECTIVE: TO EXECUTE LIFT CONTROLLER MODULE KIT TO BE USED: PLC TRAINER KIT DESCRIPTION: Lift controllers has one motor which is controlled by O2- on when its up and down movement is controlled by O3 - on up direction.O3-off down direction. The request switch of each floor is input I2, I3, I4 & I5.Where the lift position and clear is generated by O9, O8, O14 & O15 FLOOR POSITION GND 1ST 2ND 3RD INPUT I2 I3 I4 I5 OUT PUT O9 O8 O14 O15

MOTOR ON (DIRECTION) O2 MOTOR ON upward direction O3 PROCEDURE: EXECUTION FROM EPROM FOR LIFT CONTROLLER MODULE: The following procedure must be carrying out to run the program from EPROM: 1. Press RESET, Shift B.M. and 1 2. Press RESET ,then EXEC the program Note that EPROM should be inserted in the ZIF properly keeping pin no. 1 upper side. RESULT: Execution successful. PRECAUTIONS: 1. DONT TOUCH THE CONTROL PANEL WITHOUT PERMISSION. 2. READ ALL INSTRUCTION BEFORE DOING THE EXPERIMENT.

LIFT CONTROLLER MODULE

EXPERIMENT NO. 3

OBJECTIVE: SEQUENCE SWITCH FOR MOTOR MODULE REFERENCE KIT TO BE USED: PLC TRAINER KIT Alternative Indicator OR & O5 Condition of PLC switch ALL INPUTS SWITCH HIGH COM used COM2 AND COM3

DESCRIPTION: Sequence Switch is controlled by PLC by using COM2 AND COM3.When running module it the output of 220V AC. Alternatively appears on both sockets. Output can be seen in PLC Main unit on O4 & O5 PROCEDURE: EXECUTION FROM EPROM FOR SEQUENCE SWITCH MODULE: The following procedure must be carrying out to run the program from EPROM: 1. Press RESET,B.M. and 4 2. Press RESET, and then EXEC the program. RESULT: Execution successful. PRECAUTIONS: 1. DONT TOUCH THE CONTROL PANEL WITHOUT PERMISSION. 2. READ ALL INSTRUCTION BEFORE DOING THE EXPERIMENT.

SEQUENCE SWITCH FOR MOTOR MODULE REFERENCE

EXPERIMENT NO. 4

OBJECTIVE: STAR DELTA AND MOTOR CONTROL FOR 3 PHASE MODULE REFERNCE KIT TO BE USED: PLC TRAINER KIT

OUTPUT INDICATOR O4

CONDITION OF PLC SWITCH ALL INPUT

COM USED COM1 & COM3

O5 DESCRIPTION:

SWITCH HIGH

The star & delta connection for 3-phase A.C. motor and its control is done by PLC using contractors.The motor is switched ON is star for starting and then changed in delta for normal. When star connected, the applied voltage over each motor phase is reduced by a factor of 1/3 and hence the torque developed becomes 1/3 of that which would have been developed if the motor was directly connected in Delta .The line current is reduced to 1/3. Hence during starting period when motor is star connected, it takes 1/3 as much starting current and developed 1/3 as much torque would have been developed were it directly connected in Delta. We are using output O4 & O5 of PLC unit. PROCEDURE: EXECUTION FROM EPROM FOR STAR DELTA MODULE: The following procedure must be carry out to run the program from EPROM: 1. Press RESET, B.M. and 5. 2. Press RESET, and then EXEC the program. RESULT: Execution successful. PRECAUTIONS: 1. All supply voltages are of 440 V so check all the connections before power ON. 2. Do not change the connections from star to delta immediately, It may spoil the motor.

STAR DELTA AND MOTOR CONTROL FOR 3 PHASE MODULE REFERNCE

EXPERIMENT NO. 5

OBJECTIVE: TANK LEVEL CONTROL MODULE REFERENCE KIT TO BE USED: PLC TRAINER KIT INDICATOR WATER LEVEL CONDITION OF PLC SWITCH COM USED

PUMP ON

O8

LOW (P1) MEDIUM (P2) & HIGH (P3)

I2 & I3 INPUT SWITCH NEUTRAL

COM1 & COM3

DESCRIPTION: Tank level control is controlled by PLC by using COM 1 and COM 3. Note that input switch I2 and I3 should be in neutral position. The low level (P1) is always high i.e. it always dips in water tank. On running module the water is running through pump till then the water reaches at high level (P3). On touching the high level P3 the water flow will stop i.e. pump will stop. Output can be seen in PLC main unit on O8.

PROCEDURE: Execution from EPROM for Tank Level Control Module: The following procedure must be carried out to run the program from EPROM: 1. Press RESET ,B.M. and 6 2. Press RESET, and then EXEC. The program RESULT: Execution successful. PRECAUTIONS: 1. DONT TOUCH THE CONTROL PANEL WITHOUT PERMISSION. 2. READ ALL INSTRUCTION BEFORE DOING THE EXPERIMENT.

TANK LEVEL CONTROL MODULE REFERENCE

EXPERIMENT NO. 6 OBJECTIVE: FAN CONTROL MODDULE REFERENCE KIT TO BE USED: PLC TRAINER KIT SPEED O/P INDICATOR CONDITION OF PLC SWITCH COM USED

Medium Minimum Maximum

01 03 00

ALL I/P SWITCH High ALL I/P SWITCH High ALL I/P SWITCH High COM3

DESCRIPTION: A Controller is controlled by PLC by using COM3. On running Module it is controlled the speed of fan in three stage Medium, Minimum, and Maximum. These speeds can be seen in PLC Main Unit on Output LED ie: 01, 03, and 00 PROCEDURE: Execution from EPROM for Fan controller Module: The following procedure must be carrying out to run the program from EPROM: 1. Press RESET, B.M AND 2. Press RESET and then EXEC the program RESULT: Execution successful. PRECAUTIONS: 1. DONT TOUCH THE CONTROL PANEL WITHOUT PERMISSION. 2. READ ALL INSTRUCTION BEFORE DOING THE EXPERIMENT.

FAN CONTROL MODDULE REFERENCE

EXPERIMENT NO. 7 OBJECTIVE: SEVEN SEGMENT DISPLAY MODULE REFERENCE

KIT TO BE USED: PLC TRAINER KIT DISPLAY ON SEVEN SEGMENT GOOD CONDITION OF PLC SWITCH ALLNPUT SWITCH HIGH DESCRIPTION: Seven segment Display Module is controlled by PLC by using COM2. After execution of program the GOOD will be display on seven segment Display.
PROCEDURE: Execution from EPROM for Seven Segment Display Module: The following procedure must be carrying out to run the program from EPROM: 1. Press RESET, B.M. and 8 2. Press RESET, and then EXEC the program. RESULT: Execution successful. PRECAUTIONS: 1. DONT TOUCH THE CONTROL PANEL WITHOUT PERMISSION. 2. READ ALL INSTRUCTION BEFORE DOING THE EXPERIMENT.

COM USED

COM2

SEVEN SEGMENT DISPLAY MODULE REFERENCE

EXPERIMENT NO. 8 OBJECTIVE: REACTION VESSELS MODULE REFERENCE

KIT TO BE USED: PLC TRAINER KIT INDICATOR CONDITION OF PLC SWITCH HEATER ON O1 SOLONID ON I4 12 & 13 INPUT SWICTH NEUTRAL COM 1 & COM 3 COM USED

DESCRIPTION: Reaction Vessels Control is controlled by PLC by using COM 1 & COM 3. Note that input switch I2 & I3 should be in Neutral position. Set the heating temperature by thermostat, heat the water by heater. When temperature reaches at set point, heater will stop and solenoid value will work. Using solenoid value the water will flow in lower tank when level reaches lower set point the pump will on. Output can be seen in PLC main unit on (solenoid ON).
PROCEDURE: Execution from EPROM for Reaction Vessels Module

The following procedure must be carrying out to the program from EPROM. 1. Press RESET, B.M. and 7 2. Press RESET, and then EXEC the program.
RESULT: Execution successful.

PRECAUTIONS:
1. DONT TOUCH THE CONTROL PANEL WITHOUT PERMISSION. 2. READ ALL INSTRUCTION BEFORE DOING THE EXPERIMENT.

REACTION VESSELS MODULE REFERENCE

OIL POWER HYDRAULIC CUIRCUIT TRAINER KIT

COMMONNLY USED SYMBOLS USED IN HYDRAULICS & PNEUMATIC CURCUITS

EXPERIMENT NO. 9
OBJECTIVE: TO DO THE DIRECT ACTUATION OF DOUBLE ACTING CYLINDER KIT TO BE USED: OIL POWER HYDRAULIC TRAINER PROCEDURE: Connect, operate and analyze circuit as per Schematic diagram of circuit. RESULT: SUCCESSFUL EXECUTION OF THE EXPERIMENT DONE. PRECAUTION: 1. DONT STAND INFRONT OF THE CONTROL PANEL IN OPERATING CONDITION. 2. OPERATE THE SYSTEM UNDER FACULTYS GUIDANCE

DIRECT ACTUATION OF DOUBLE ACTING CYLINDER

EXPERIMENT NO. 10
OBJECTIVE: TO DO THE DIRECT ACTUATION OF HYDRAULIC MOTOR KIT TO BE USED: OIL POWER HYDRAULIC TRAINER PROCEDURE: Connect, operate and analyze circuit as per Schematic diagram of circuit. RESULT: SUCCESSFUL EXECUTION OF THE EXPERIMENT DONE. PRECAUTION: 1. DONT STAND INFRONT OF THE CONTROL PANEL IN OPERATING CONDITION. 2. OPERATE THE SYSTEM UNDER FACULTYS GUIDANCE

DIRECT ACTUATION OF HYDRAULIC MOTOR

EXPERIMENT NO. 11
OBJECTIVE: TO DO THE METER IN CIRCUIT WITH 4/2 SOLENOID VALVE FOR DOUBLE ACTING CYLINDER KIT TO BE USED: OIL POWER HYDRAULIC TRAINER PROCEDURE: Connect, operate and analyze circuit as per Schematic diagram of circuit. RESULT: SUCCESSFUL EXECUTION OF THE EXPERIMENT DONE. PRECAUTION: 1. DONT STAND INFRONT OF THE CONTROL PANEL IN OPERATING CONDITION. 2. OPERATE THE SYSTEM UNDER FACULTYS GUIDANCE

METER IN CIRCUIT WITH 4/2 SOLENOID VALVE FOR DOUBLE ACTING CYLINDER

EXPERIMENT NO. 12
OBJECTIVE: TO DO THE METER OUT CIRCUIT WITH 4/3 SOLENOID VALVE FOR DOUBLE ACTING CYLINDER KIT TO BE USED: OIL POWER HYDRAULIC TRAINER PROCEDURE: Connect, operate and analyze circuit as per Schematic diagram of circuit. RESULT: SUCCESSFUL EXECUTION OF THE EXPERIMENT DONE. PRECAUTION: 1. DONT STAND INFRONT OF THE CONTROL PANEL IN OPERATING CONDITION. 2. OPERATE THE SYSTEM UNDER FACULTYS GUIDANCE

METER OUT CIRCUIT WITH 4/3 SOLENOID VALVE FOR DOUBLE ACTING CYLINDER

EXPERIMENT NO. 13
OBJECTIVE: TO DO THE METER OUT CIRCUIT WITH 4/3 SOLENOID VALVE FOR SERVO MOTOR KIT TO BE USED: OIL POWER HYDRAULIC TRAINER PROCEDURE: Connect, operate and analyze circuit as per Schematic diagram of circuit. RESULT: SUCCESSFUL EXECUTION OF THE EXPERIMENT DONE. PRECAUTION: 1. DONT STAND INFRONT OF THE CONTROL PANEL IN OPERATING CONDITION. 2. OPERATE THE SYSTEM UNDER FACULTYS GUIDANCE

METER OUT CIRCUIT WITH 4/3 SOLENOID VALVE FOR SERVO MOTOR

POST PRACTICAL QUESTIONS 1. A double acting cylinder has a piston diameter of 2 inches and a rod diameter of 3/4". The piston stroke is 8 inches. a) If oil can be supplied to either end of the cylinder at a pressure of 1000 psi and a flow of 3 gal/min, calculate the force that can be developed and time of travel (in seconds) during extension and retraction. b) Briefly explain why the forces and speeds are different during extension and retraction. c) Show whether the power developed is the same or different during extension and retraction.. Use your values of forces and time. 2. Briefly describe the difference between a linear hydraulic cylinder and a regenerative one. a) Will a single acting cylinder work in either case and, if not, why not? b) What differential piston area ratio is required for the regenerative system? Will any other ratio work? 3. Describe the operation of the circuit for speed control of the hydraulic rotary valve motor circuit 4. For the Hydraulic Motor and cylinder circuit answer the following questions. a). Describe the sequence of events as the directional valve is move to its various positions. b). Is this an "open" or "closed" center system? c). Is the motor reversible or does it always run in the same direction? d). Can the motor speed be varied? How and when can it be varied? e). Under what conditions can the motor speed not be varied?

PROGRAMMABLE LOFIC CONTROLLER WITH PNEUMATIC CIRCUITS In automation, mechatronics plays a great role. Suppose we want to use sensor inputs and give outputs to motors to control certain machine or plant as shown in Fig 1. Before electronics becomes popular and cheaper, it has been controlled using pneumatic and/or hydraulic values. Now a days these are replaced by mechatronics systems. Fig 1.2 In mechatronics, we use electronics in four different ways: 1.Programmable logic controllers -PLC is a digital electronic device that uses a programmable memory to store instructions for obtaining logic, sequencing, timing, counting and arithmetic in order to control machine and processes. The advantage of using PLC is that it is possible to modify a control system without having the input and output devices rewired and without using new or modified control valves in order to change the required logic. The only requirement being that an operator has to key in a different set of instructions. The result is a flexible system that can be used in control systems that vary quite widely in their nature and complexity. 2. Electronics circuits-This is commonly used in mass products or large batch products since these circuits are especially designed for the purpose. Ex. Control cards, motor driving circuits. 3. Computer controlled machines-Computer acts as a controller taking inputs from sensors and giving the necessary output signals to the actuators or motors.

MOTORS

CONTROLLERS

SENSORS

Fig 1.2 MECHATRONICS SYSTEM

4. Micro controllers- it is a programmable integrated circuit (IC). Functions of the micro controllers could be quite similar to PLCs. It is more compact, more flexible in programming and much cheaper, but more programming is required and less number of inputs and outputs in general relative to a PLC. All these devices have advantages and limitations over each other and hence choice of the controlling method is application dependent. All the above mentioned devices consist of electronic circuits and they consider digital inputs and digital outputs though some PLCs can obtain a kind of analogue inputs and outputs. All the above three mentioned Controllers generally consider a digital voltage inputs and a voltage output. Sensors and Transducers The term sensor is used for an element that produces a signal relating to the quantity being measured. Transducers are defined as elements that when subject to some physical change experiences a related change. Thus sensors are transducers. However, a measurement system may use transducers, in addition to the sensor, in other part of the system to convert signals from one form to other form. Signal conditioners Sensors can give different kinds of output from the sensing devices and these outputs have to be processed or converted as a voltage and the voltage output may have to be converted or processed to other type of signals in mechatronics systems. This device is known as a signal conditioner. Operational amplifier and A/D converter are two examples of such devices. Signal conditioners act a major role between controller and sensors as well as controller and motor or actuators. Pneumatic Systems In early systems, control functions were obtained through pneumatic valves and today replaced by electronic circuits and still pneumatic signals are still popular and used to control final control elements because such signal can be used to actuate large valves and other high power control devices. The main drawback of the pneumatic systems is however the compressibility of air. Pneumatic is not only used as a control mechanism, but also as actuators and in some cases logic is conducted through a PLC or an electronic circuit with electro-pneumatic valves to convert the signals. Hydraulic Systems Hydraulic Systems are used basically for actuators and motors consisting high power. In Heavy Machinery equipments hydraulic actuators are used to conduct many tasks. Hydraulic control valves are used to change the direction of the fluid by giving manual, electro-mechanical or/and pneumatic signals. However, there are hazards in using hydraulics due to oil leaks that does not matter in pneumatic systems.

Data bus Program panel Address bus Control bus Input channels CPU Memory I/O unit

Output channels

Fig: PLC Architecture

Programmable Logic Controllers PLC is similar to using a computer but has certain features that are specific to their use as controllers. These are: 1. They are rugged and designed to withstand vibrations, temperature, humidity and noise. 2. The interfacing for inputs and outputs is inside the controller. 3. They are easily programmed and have an easily understood programming language. Programming is primary concerned with logic and switching operations.PLCs were first conceived in 1968. They are now widely used and extend from self-contained units for use with around 20 digital inputs/outputs to modular systems that can be used for large number if inputs/outputs, handle digital or analogue inputs/outputs and also carry out PID control modes. Electronic Control Circuits Basic electronic control circuits consist of two types, namely combinational logic gates and sequential logic gates. The advantage of electronic control circuits is construction is cheaper than pneumatic values, hydraulic values or programmable logic controller, but design is quite costly. In this course, we will only look at electronic controllers although electronic circuits are used as signal -conditioning device such as amplifies, voltage dividers or A/D converters.

What is a PLC?
A Programmable Logic Controller, or PLC for short, is simply a special computer device used for industrial control systems. They are used in many industries such as oil refineries, manufacturing lines, conveyor systems and so on. Where ever there is a need to control devices the PLC provides a flexible way to "softwire" the components together. The basic units have a CPU (a computer processor) that is dedicated to run one program that monitors a series of different inputs and logically manipulates the outputs for the desired control. They are meant to be very flexible in how they can be programmed while also providing the advantages of high reliability (no program crashes or mechanical failures), compact and economical over traditional control systems.

A Simple Example
Consider something as simple as a switch that turns on a light. In this system with a flick of the switch the light would turn on or off. Beyond that though there is no more control. If your boss came along and said I want that light to turn on thirty seconds after the switch has been flipped, then you would need to buy a timer and do some rewiring. So it is time, labor and money for any little change.

A PLC Saves the Day

Now consider the same device with a PLC in the middle. The switch is fed as an input into the PLC and the light is controlled by a PLC output. Implementing a delay in this system is easy since all that needs to be changed is the program in the PLC to use a delay timer.

This is a rather simple example but in a larger system with many switches and lights (and a host of other devices) all interacting with each other this kind of flexibility is not only nice but imperative. Hopefully a light bulb has now turned on over your head.

Programming a PLC
In these modern times a PC with specially dedicated software from the PLC manufacturer is used to program a PLC. The most widely used form of programming is called ladder logic. Ladder logic uses symbols, instead of words, to emulate the real world relay logic control, which is a relic from the PLC's history. These symbols are interconnected by lines to indicate the flow of current through relay like contacts and coils. Over the years the number of symbols has increased to provide a high level of functionality. The completed program looks like a ladder but in actuality it represents an electrical circuit. The left and right rails indicate the positive and ground of a power supply. The rungs represent the wiring between the different components which in the case of a PLC are all in the virtual world of the CPU. So if you can understand how basic electrical circuits work then you can understand ladder logic. In this simplest of examples a digital input (like a button connected to the first position on the card) when it is pressed turns on an output which energizes an indicator light.

The completed program is downloaded from the PC to the PLC using a special cable thats connected to the front of the CPU. The CPU is then put into run mode so that it can start scanning the logic and controlling the outputs. On a program ladder diagram are two basic types of instructions: Input Instructions: An instruction that checks, compares, or examines specific conditions in your machine or process. Output Instructions: An instruction that takes some action, such as turn on a device, turn off a device, copy data, or calculate a value.

Branch A branch is two or more instructions in parallel.

There is no limit to the number of parallel branch levels that you can enter. This example shows a parallel branch with five levels. The main rung is the first branch level, followed by four additional branches.

You can nest branches to as many as 6 levels. This example shows a nested branch. The bottom output instruction is on a nested branch that is three levels deep.

Rung Condition : The controller evaluates ladder instructions based on the rung condition preceding the instruction (rung-condition-in).

Only input instructions affect the rung-condition-in of subsequent instructions on the rung. If the rung-condition-in to an input instruction is true, the controller evaluates the instruction and sets the rung-condition-out to match the results of the evaluation.

If the instruction evaluates to true, the rung-condition-out is true. If the instruction evaluates to false, the rung-condition-out is false.

An output instruction does not change the rung-condition-out.

If the rung-condition-in to an output instruction is true, the rung-condition-out is set to true.

If the rung-condition-in to an output instruction is false, the rung-condition-out is set to false

INTRODUCTION TO PNEUMATICS
The reason for using pneumatics, or any other type of energy transmission on a machine, is to perform work. The accomplishment of work requires the application of kinetic energy to a resisting object resulting in the object moving through a distance. In a pneumatic system, energy is stored in a potential state under the form of compressed air. Working energy (kinetic energy and pressure) results in a pneumatic system when the compressed air is allowed to expand. For example, a tank is charged to 100 PSIA with compressed air. When the valve at the tank outlet is opened, the air inside the tank expands until the pressure inside the tank equals the atmospheric pressure. Air expansion takes the form of airflow. To perform any applicable amount of work then, a device is needed which can supply an air tank with a sufficient amount of air at a desired pressure. This device is positive displacement compressor.

Common Types of Cylinders

There are many different cylinder types. The most common are listed below: Single acting cylinder - a cylinder in which air pressure is applied to the movable element (piston) in only one direction.

Spring return cylinder - a cylinder in which a spring returns the piston assembly.

Ram cylinder - a cylinder in which the movable element is the piston rod.

Double acting cylinder - a cylinder in which air pressure may be alternately applied to the piston to drive it in either direction.

Double acting double rod cylinder - Double acting cylinder with a piston rod extending form each end. The piston rods are connected to the same piston. Double rod cylinders provide equal force and speed in both directions.

Directional Control Valves

To change the direction of airflow to and from the cylinder, we use a directional control valve. The moving part in a directional control valve will connect and disconnect internal flow passages within the valve body. This action results in a control of airflow direction. The typical directional control valve consists of a valve body with four internal flow passages within the valve body and a sliding spool.

Shifting the spool alternately connects a cylinder port to supply pressure or the exhaust port. With the spool in the position where the supply pressure is connected to port A and port B is connected to the exhaust port, the cylinder will extend. Then, with the spool in the other extreme position, supply pressure is connected to port B and port A is connected to the exhaust port, now the cylinder retracts. With a directional control valve in a circuit, the cylinder's piston rod can be extended or retracted and work performed.

Functional Types of Directional Control Valves

One method of classifying a directional control valve is by the flow paths that are set up in its various operating conditions. Important factors to be considered are the number of individual ports, the number of flow paths the valve is designed for and internal connection of ports with the movable part.

Two-Way Directional Valve

A two-way directional valve consists of two ports connected to each other with passages, which are connected and disconnected. In one extreme spool position, port A is open to port B; the flow path through the valve is open. In the other extreme, the large diameter of the spool closes the path between A and B; the flow path is blocked. A two-way directional valve gives an on-off function.

Three-Way Directional Valve:

A three-way directional valve consists of three ports connected through passages within a valve body that are shown here as port A, port P and port Ex. If port A is connected to an actuator, port P to a source of pressure and port Ex is open to exhaust, the valve will control the flow of air to (and exhaust from) Port A. The function of this valve is to pressurize and exhaust one actuator port. When the spool of a three-way valve is in one extreme position, the pressure passage is connected with the actuator passage. When in the other extreme position, the spool connects the actuator passage with the exhaust passage.

VARIOUS TYPES OF VALVE SYMBOLS:

ISO SYMBOLS FOR AIR TREATMENT EQUIPMENT

Pneumatics Circuits and Applications

Pneumatic circuit design consideration: When analyzing or designing a pneumatic circuits, the following four important considerations must be taken into account: Safety of operation Performance of desired functions Efficiency of operation Costs The typical cost for the compressing air to 100 psig is about $0.35 per 1000 ft^3 of standard air.
BASIC PNEMATICS LAYOUT:

Example : Air pilot control of double-acting cylinder Purpose: To operate a double-acting cylinder remotely through the use of an air pilot-actuated DCV.

EXPERIMENT NO.14

Objective: Design a simple pneumatic direct control circuit to open and close the Gate of a factory. By operating a push button valve, gate should open or close.
Component List a) FRL Unit. b) 3/2 Push Button Valve. c) Single Acting Spring Return Cylinder. Description: a) FRL Unit (Filter Regulating and Lubricating Unit): This is positioned between Air source and the components. This unit plays an important roll in pneumatic systems. The FRL Unit provides compressed clean and oil enriched air at a constant pressure to the system. b) 3/2 Pus Button Valve: This component has three air ports and two positions (pressed or released). P is an air inlet port, A is a working port (Out Let Port) and R is an Exhaust Port. The valve is activated by a manual push button and returned by spring force. c)Spring Return Cylinder: When pressurized air enters through Port, it pushes the piston out of the cylinder, thereby contracting the spring. When no air pressure is applied, the spring expands, drawing the piston back into the cylinder. Procedure: Select the components from component library. Load the single acting cylinder, place at the top of the Screen. Load 3/2 push button valve and place between cylinder and conditioning Unit (FRL). The FRL Unit will be at the bottom by default. Before starting simulation FRL unit parameters (i.e. Pressure and Flow) are to be set by double clicking on it. Connect the components as per the circuit, as show in Fig.No.1 Click on Simulation icon or from main menu to start simulation and observe the following. Result: When the push button is pressed, the spring in the valve is compressed, allowing air to flow through the valve to the cylinder. Air passes through the rear port of the cylinder and pushes the piston rod out. (Thereby opening the gate). When the push button released, the spring in the valve expands. Air is exhausted from the cylinder and airflow to the cylinder is blocked. The spring in the cylinder is able to expand; the piston rod retracts (thereby closing the gate)

Fig no:1

EXPERIMENT NO. 15 Objective: Design a pneumatic circuit using a double acting cylinder and 5/2 Air Spring Valve to open the main gate of a factory which can be controlled by a security personnel from the security room.
Component List: a) b) c) d) Description: 5/2 Air Spring Valve: This component has five airports and two positions. P is an air inlet port; A& B are working ports (Outlet ports). R& S are air Exhaust Ports and Y is pilot Operated port. Double Acting Cylinder: This cylinder has two inlet ports A & B. Air entering from A port extends the piston, Air at the other side is exhausted through B port. If air enters through B port piston rod of the cylinder will retract while air exhausts from the A port. Procedure: Load the double acting cylinder and place at the top of the screen. Load 5/2 Air Spring Valve and place below the cylinder. The FRL Unit will be at the bottom by default. Connect the components as per the circuit, as show in fig. No.2 Result: When the Push button valve is activated, allowing air to flow through the 5/2air spring valve to the rear port of the cylinder then piston rod extends. (There by opening the gate). When the Push Button is released, allowing the air to flow through the valve to the front port of the cylinder. The cylinder piston rod retracts. FRL Unit: 5/2 Air Spring Valve. 3/2 Push botton Valve Double Acting Cylinder.

Fig no:2

EXPERIMENT NO. 16

Objective: Design a pneumatic circuit using a double acting cylinder and 5/2

Air Spring valve to lift the carton boxes at the loading point. The raising and lowering speeds are to be adjustable separately.
List of components: a) FRL Unit b) 5/2 Air Spring Valve c) 3/2 Push button Valve. d) Double Acting Cylinder e) Flow Control valves -2 Nos. Description: a) Flow Control Valve: This valve are used to regulate airflow. Example, to control the piston speeds of the cylinder. The air can flow only via the cross section, which is adjustable by means of the throttle screw. The user can change the settings by double clicking on it. The settings vary from 2 to 16. Procedure: Select the components from components library and place the double acting cylinder at the top of the Screen. 5/2 air Spring valve below the cylinder. The Flow Control Valve is placed between cylinder and Air Spring Valve. The FRL Unit will be at the bottom by default. Connect the components as per the circuit, as show in Fig No.3. Result: When the Push Button is pressed, allowing air to flow through the valve to the one port of the cylinder. The air enters from the rear port of the cylinder and pushes the piston rod out. (Thereby opening the gate). When the push-button Valve released, allowing the air to flow through the valve to the front port of the cylinder. Then the cylinder piston rod retracted (thereby gate is closed). Adjust the throttle valve screws and observe the variation in piston speed.

Fig.No.3