Manufacturing Automation using PLCs

CHAPTER 6 Pneumatic Logic Sensors and Actuators

Chapter 6: Pneumatic Logic Sensors and Actuators

6.1 Pneumatic limit, push-button and emergency stop valves

6.2 Pneumatic directional pilot control valve
6.3 Solenoid actuation directional control valves
6.4 Pneumatic directional control valve symbols
6.5 Cylinder (cylinders) actuation circuit
6.5.1 Single acting cylinder actuation
6.5.2 Double acting cylinder actuation using pilot valve actuation

Pneumatic Logic Sensors and Actuators

6.1
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CHAPTER 6 Pneumatic Logic Sensors and Actuators

Pneumatic control system is frequently used in building automatic assembly machines.

Pneumatic sensors and actuators are used in such control system. Electric current flows
between logic sensors and actuators during machine control sequence. In other hands,
pressure airline flows between pneumatic sensors and actuators during machine control
sequence. In most cases, both control systems are used to build the machine control
sequence. Although, hydraulic control system can also be used, this will not be
considered in current Chapter.
6.1 Pneumatic limit, push-button and emergency stop valves
The main structure of the limit valves, push button and emergency stop valves are
the same. Pneumatic limit valves are the equivalent of mechanical limit switches.
Furthermore, the pneumatic push button and emergency stop valves are equivalent
of mechanical push button and emergency stop mechanical switches. The main
difference between the pneumatic limit valves and the mechanical switches, in the
latter, the actuating arm or plunger shifts a so-called directional-control valve rather
than electric contacts. Same thing is applied for push button and emergency valves.

For example, consider Fig. 6.1, which shows a so-called 3/2 limit valve (meaning 3
connections and 2 positions valve). The valve shown as normally closed, so that the
outlet line is exhausted to atmosphere when the valve is not actuated. When the
valve is actuated, the roller is depressed against the return spring at the bottom, so
that the valve opens and passes supply pressure to the outlet line.

Exhaust
NC electro-
Output mechanical switch
Supply
pressure

NC
lim
Fig. 6.1 Normally closed limit valve
it structure, ISO and ANSI symbol and the
corresponding electro-mechanicalval switch symbol.
ve

Fig. 6.2 illustrates another pneumatic limit valve called 5/2 limit valve (meaning 5
connections and 2 positions valve), which has two independent outlet lines, one is
normally open and is the second normally closed. Such a valve is analogous to limit
mechanical switch with changeover contacts (NO and NC contacts switch).

For both cases, the limit valve can be used as push-button valve and do the same
stated functions, as shown in Fig. 6.2.

6.2 Pneumatic directional pilot control valve

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CHAPTER 6 Pneumatic Logic Sensors and Actuators
Most directional-control valves are of the spool and sleeve type. Fig. 6.3, shows a
5/2 spool valve (schematically). When the spool position or pilot line has been
pressurized by p1 line. Flow line between A & D ports, and B & E posts are passed,
while C is blocked. If pilot line p2 is pressurized, the spool shifted to the lift with
corresponding change in flow paths as illustrated in Fig 6.3. Also, Fig. 6.3 shows
also the ISO or ANSI standard symbol of 5/2 way directional valve. This type of
directional valve can be used as SET-REST mechanical memory in pneumatic
circuit.

Output Output
Exhaust Exhaust
A+ A+
Supply Supply
pressure pressure
A- A-
Exhaust Exhaust

NC (A+)
NC (A+)
COM COM
NO (A-)
Equivalent changeover mechanical NO (A-)
limit switch Symbol.
Equivalent RLL changeover
mechanical limit switch Symbol.

D E
P1 P2

D E
A B C
Fig. 6.2 5-ways two positions directional limit valve; internal structure, ISO and
ANSI valve symbol, corresponding electromechanical switch symbol, and types
push buttons. D E A B C

P1 P2

A B C
6.3
Fig. 6.3 5-ways two positions directional pilot valve; internal structure, and ISO-
ANSI valve symbol.
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CHAPTER 6 Pneumatic Logic Sensors and Actuators

6.3 Solenoid actuation directional control valves

The main difference between the solenoid actuation directional control valve and
pilot control valve, is the way of displacement of the valve spool. Spool valve
displacement is carried out using two pressurized air p1 and p2 in case of the pilot
control valve. While solenoid and spring mechanisms are used to displace the spool
valve in case of the solenoid actuation directional valve (or simply solenoid
directional valve) as shown in Fig. 6.4. Similarly, solenoid actuation can also be
used with 3/2 ways directional valve.

Fig.Pneumatic
6.4 6.4 Solenoiddirectional
actuation directional
control control valve (5/3 ways).
valve symbols
These pneumatic valves that discussed so far called directional control valves and
used as ON/OFF valves to control the airflow to the actuators. Most directional-

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CHAPTER 6 Pneumatic Logic Sensors and Actuators
control valves have two or three discrete ports or positions. Fig. 6.5, shows the
international ISO or United States ANSI standard symbols for three connections
two position valve, 3/2 valve. The two rectangles represent the two discrete
positions of the valve. Since the connection tubes are drawn in this case attached to
the left rectangle, this means that the valve is presently in the left position.

In Fig. 6.5, there are three connections, or valve ports, labeled as A, B and C,
respectively. As long as the valve remains in the left position, left rectangle, there is
airflow from port A to C, while port B is blocked. When this valve is shifted to its
right position, right rectangle, port A blocked, while port B and C are connected.
The arrowheads shown on the symbol are optional, they indicating the airflow
directions.
C D E

A B A B C

Fig. 6.5 Illustration of ISO and ANSI symbols of 3/2 and 5/2 ways
directional valve.

Fig. 6.5, shows the symbol of a five connections two position (5/2) valve. In the left
position, port A and D are connected, and likewise port B and E, while port C is
blocked. In the right position, port A is blocked, while port B is connected to D, and
port C to E.
In addition to the rectangles showing the valve positions, the symbol must also indicate
how the valve is shifted or actuated. The symbols for common actuation methods shown in
Fig. 6.6. As illustrated in Fig 6.6, the actuation symbols are for only one valve position.
Actually, the opposite actuation must also exist, because otherwise the valve could never
shifted back to its original position. various combination are available. For example,
Fig( 6.7a) shows a valve with pilot-pressure actuation and return spring. In Fig 6.7(b, a)
solenoid is substituted for the pilot line. Fig 6.7(c & d), no return spring, instead the valve
is shifted back by activating the opposite pilot line or solenoid, respectively.

Spring return Lever

Mechanical-roller

Push button Foot pedal

Electric(solenoid)

Manual Mechanical(plunger)
Pneumatic(pilot)
Fig. 6.6 Common methods used to actuating directional valves.
Pneumatic
(pilot
Fig 6.7(e) shows additional position to the 5/2 directional valve. The mid-position blocks
all the ports. This type of valves is called 5/3 directional valves (5 connections, 3
positions). The original position (or normal position) of the valve at the middlesignal
(blocked
ports position). amplifier)

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CHAPTER 6 Pneumatic Logic Sensors and Actuators
Fig. 6.8, shows some additional pneumatic symbols, and most should be self-explanatory.
For example, air supply symbol used as common (all points connected to air supply).
Check valve symbol represents a one-direction air flow valve. The shuttle valve has free-
float ball or disk able to seal either of two seats, if either input A or B is pressurized, the
ball seals the opposite seat, hence output C is high (this type of valve used as OR gate,
where the C output is high only when one of the input A or B high).

Pilot line & return spring (5/2) valve.

Solenoid & return spring (5/2) valve.

Double pilot lines (5/2) valve.

Double solenoid (5/2) valve.

Double solenoid & return springs (5/3) valve.

Fig. 6.7 Valve symbols for five different ways of valve actuation.

Vent to atmosphere
Single-acting Air compressor
cylinder with a
return spring
Pressure Check valve
Regulator unidirection
Double-acting
cylinder

Bidirectional
Shuttle valve
air motor Air supply

Variable
Restriction restriction
(fixed) return)
Single-act-cylinder(spring (needle valve)

Fig. 6.8 Additional pneumatic symbols.

6.5 Cylinder (cylinders) actuation circuit
Push-button valve
6.5.1 Single acting cylinder actuation

P1

6.6
3/2 way directional valve(cylinder actuating valve)

Fig. 6.9 Actuating circuit of single-acting cylinder.

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CHAPTER 6 Pneumatic Logic Sensors and Actuators

Operation :
 When push button pressed, pilot line of the 3/2 cylinder actuating valve is
pressurized.
 Air pass the left cylinder side, results in piston moved forward.
 When push button valve release, the 3/2 valve return to it’s original position
and the piston return using spring force to it’s original position(shown position).
 The circuit is drawn in it’s initial position.

- A +

.a+
START
A- A+

6.5.2 Double acting cylinder actuation using pilot valve actuation

VA

Fig. 6.10 Actuating circuit for double-acting 6.7

cylinder using 5/2 pilot valve VA, 3/2 push button
valve (START) and 3/2 limit valve ( a+ ) for
machine sequence START, A+,A- .
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CHAPTER 6 Pneumatic Logic Sensors and Actuators

Operation :
 At the beginning, all elements positioned as shown in Fig. 6.10.
 Push button valve pressed, pilot line A+ is pressurized, shifting the 5/2 pilot
valve to it’s right rectangle symbol position. This will pressurized the A+ of the
cylinder room, causing the piston moves forwards.
 When push button released and pilot line A+ is vented, the 5/2 cylinder valve
remains in it’s new position (setting mechanical memory).
 At the end of the cylinder stroke, piston rod actuating limit valve 3/2 ( a+ ), to
which pressurized pilot line A-, causing the cylinder return to backward position
automatically (original position), hence, resetting the mechanical memory.

PROBLEMS

6.1) “Two-hand safety circuit”, is a pneumatic circuit used for actuating

dangerous equipment such as punch press, it has two push button valves
mounted sufficiently apart so that both cannot be reached with one hand.
Both push buttons must be pressed simultaneously to actuate the press (or

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CHAPTER 6 Pneumatic Logic Sensors and Actuators
double-acting cylinder). Hence, this will forces the operator to withdraw
both hands from the dangerous area before the press descends. Draw
pneumatic circuit to actuates double acting cylinder using three pneumatic
valves; the first and the second valves are two 3/2 push button valves, and
the third valve VA is 5/2 directional valve with one pilot line and return
spring ?

Ans) - A +

START-1 START-2

A- A+

VA

6.2) Draw the ISO or ANSI symbol of 3/2 limit valve with normally open
design structure?

Ans)
Exhaust Supply
pressure
Output Output
Supply Exhaust
pressure

NC
lim NO
it lim
val it
ve val
ve

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CHAPTER 6 Pneumatic Logic Sensors and Actuators

6.3) Draw a pneumatic circuit to drive two double acting cylinders ( A and B )
using two 5/2 pilot type valves, push button 3/2 valve and two 3/2 limit

A −
valves using the following control sequence : START , A , B , −  .
+ +

B 
Ans)

- A +
.a+
START
A- A+

VA

- B +
.b+

B- B+

VB

6.4) Develop the pneumatic network for R/S Flip-Flop using Pilot 5/2 valve and
2 push-button valves 3/2 type with spring return, draw the pneumatic
network circuit ?

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CHAPTER 6 Pneumatic Logic Sensors and Actuators
6.5) Develop the pneumatic network circuit using for the following pneumatic
machine sequence:

A A
+−

START, + ., − .

B   B 
6.6) Develop a pneumatic network to drive a single acting cylinder using one or
both two START push buttons, 3/2 type?

6.7) Develop a pneumatic network circuit to run the following pneumatic

machine sequence:

+ A− 
+ B   
START,A , +  ., B − 
 C   C− 

6.8) Develop pneumatic network circuit for AND, OR and NOT gates?

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Laboratory 6.1 : Develop the pneumatic logic network for question 6.3 using the
pneumatic tools given lab.

6.12