DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE

DWM4302 PNEUMATICS AND HYDRAULICS

TOPIC 1.0 : FUNDAMENTALS OF PNEUMATICS

1.1 The physical properties of air

1.2 The characteristics of air.

1.3 The control theory

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DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
DWM4302 PNEUMATICS AND HYDRAULICS

FUNDAMENTALS OF PNEUMATICS

Objectives:-

At the end of this lesson the students will be able to:

1. Introduce physical properties of air

2. Identify characteristics of air
3. Relate control theory

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DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
DWM4302 PNEUMATICS AND HYDRAULICS

1.0.1 Pneumatics in review

Pneumatics has long since played an important role as a technology in the performance of
mechanical work. It is also used in the development of automation solutions. The word
Pneumatics is derived from Latin Word “PNEUMO” means “Breathing”.

To be able to control machinery and installations necessitates the construction of a generally

complex logic interconnection of statuses and switching conditions. This occurs as a result of
the interaction of sensors, processors, control elements and actuators in pneumatic or partly
pneumatic systems.

1.0.2 What Can Pneumatics do?

Operation of heavy or hot doors.

Unloading of hoppers in building, steel making, mining and chemical industries.
Forming operations of bending, drawing and flattening.
Bottling and filling machines.
Pneumatic robots.
Component and material conveyor transfer.
Air separation and vacuum lifting of thin sheets.

Figure 1.1 show the application of pneumatic component at chip bonding process which
consists of a vacuum unit.

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DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
DWM4302 PNEUMATICS AND HYDRAULICS

1.0.3 The Advantages and Limitations of Pneumatic

 It has several operation modes; can be fully automated, manually operated and semi
automated mode.
 It is clean, suitable for several processes which are very sensitive, especially for
hazardous chemicals and electronic components.
 The equipments are very cheap compared to other methods.
 The accuracy of the end results is moderate.
 Reduce production time and cost – mass production.
 There is no other waste produced from the operating system except air.
 Compress is relatively insensitive to temperature fluctuation. This ensures reliable
operation, even under extreme condition (depend on protection material).

However, pneumatic technology also has their own limitations. Listed below are the
limitations of pneumatic technology:

 Only clean air with lowest humidity is allowed to be in pneumatic system. So,
compress air need good preparation to filter any kind of dirt and condensate.
 It is seldom to get uniform and constant piston speed with compressed air.
 It has the limitation in producing the output force. It is suitable for non-heavy duty
purpose.
 The exhaust air is very noisy.
 Compressed air is very expensive in terms of conveying the power but the high price
is remunerated by the cheap pneumatic equipments, fast and efficient production.

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DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
DWM4302 PNEUMATICS AND HYDRAULICS

1.1.0 The physical properties of air

Air is an abundant gas mixture with the following composition:

 Nitrogen approx. 78 vol. %
 Oxygen approx. 21 vol. %
 Traces Gases approx. 1 vol. %
It also contains traces of carbon dioxide, argon, hydrogen, neon, helium, krypton and xenon.

To assist in the understanding of the natural laws as well as the behaviour of air, the physical
dimensions which are employed. The data is taken from the “International System of Units”,
SI for short.

The pressure prevailing directly on the earth’s surface is known as atmospheric pressure
(pamb). This pressure is also referred to as reference pressure. The range above this pressure
is known as excess pressure range (pe > 0), the range below is referred to as vacuum range
(pe < 0). The atmospheric differential pressure pe is calculated according to the
formula:
pe = pabs – pamb
This is illustrated by the following diagram:

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DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
DWM4302 PNEUMATICS AND HYDRAULICS

Atmospheric pressure does not have a constant value. It varies with the geographical location
and the weather.
The absolute pressure pabs is the value relative to pressure Zero - Vacuum. It is equal to the
sum of the atmospheric pressure and the excess pressure or vacuum. In practice, pressure
gauges which only indicate the excess pressure are generally used. The absolute pressure
value pabs is approximately 100 kPa (1 bar) higher.
Generally, in pneumatics all data concerning air quantity refers to the socalled standard state.
According to DIN 1343, the standard state is the status of a solid, fluid or gaseous substance
defined by standard temperature and pressure.
Standard temperature Tn = 273.15 K, tn = 0 °C
Standard pressure pn = 101325 Pa = 1.01325 bar

1.2.0 Characteristics of air

A characteristic of air is its minimal cohesion, i.e. the forces between the air molecules are to
be disregarded for operating conditions usual in pneumatics. In common with all gases, air
has no particular shape. Its shape changes with the slightest resistance, i.e. it assumes the
shape of its surroundings.

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DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
DWM4302 PNEUMATICS AND HYDRAULICS

Air can be compressed and it endeavours to expand. The applicable relationship is given in
Boyle-Mariottes Law. At constant temperature, the volume of a given mass of gas is
inversely proportional to the absolute pressure, i.e. the product of absolute pressure and
volume is constant for a given mass of gas.
p1 • V1 = p2 • V2 = p3 • V3 = Constant

The general gas equation is a combination of all three:

In the case of a given mass of gas, the product of pressure and volume divided by the
absolute temperature is constant. This general gas equation results in the previously
mentioned laws, if one of the three factors p, V or T is kept constant in each case.
Pressure p constant ⇒ isobar changes
Volume V constant ⇒ isochore changes
Temperature T constant ⇒ isothermal changes

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DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
DWM4302 PNEUMATICS AND HYDRAULICS

1.3.0 Pneumatics and control system development

The product development in pneumatics can be considered in a number of areas:

 Actuators
 Sensors and input devices
 Processors
 Accessories
 Control systems

1.3.1 Structure and signal flow of pneumatic systems

Pneumatic systems consist of an interconnection of different groups of elements.

This group of elements forms a control path for signal flow, starting from the signal section
(input) through to the actuating section (output). Control elements control the actuating
elements in accordance with the signals received from the processing elements.

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DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
DWM4302 PNEUMATICS AND HYDRAULICS

The primary levels in a pneumatic system are:

 Energy supply
 Input elements (sensors)
 Processing elements (processors)
 Control elements
 Power components (actuators)

The elements in the system are represented by symbols which indicate the function of the
element.

Pneumatic control system

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DWM4302 PNEUMATICS AND HYDRAULICS

A directional control valve can be used as an input, processing or control element. The
distinguishing feature for the allocation of the individual components to the respective groups
of elements is the configuration within a pneumatic system.

Circuit diagram and pneumatic elements

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DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
DWM4302 PNEUMATICS AND HYDRAULICS

Exercise

1. What is the pneumatics system?

a. Component and material conveyor transfer
b. Heavy duty works
c. Use compressed air as a medium of transfer of power

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