Basic Pneumatic System

1
Assembly & Maintenance of

Pneumatic & Hydraulic System
(SED 23103)
Basic Automation System
(SRD 23403)
Malaysian Spanish Institute

MSI Pneumatic System
v5
Assembly & Maintenance of Pneumatic & Hydraulic System
(SED 23103) - (Assessment)
1. Basic Pneumatic System
Technical Report 10%
Mini Project 10%
Test 10%
Exam Practical 20%

2. Basic Hydraulic System
Mini Project 10%
Test 10%
Exam Practical 20%

Total Marks (SED 23103)
Mini Project 20%
Test 20%
Exam Practical 40%
100%
2

MSI Electrical System
(SED 23103) - (Assessment)
Pneumatic Power
Pneumatic Control
Pneumatic Actuator

Hydraulic Power
Hydraulic Control
Hydraulic Actuator

End of Course
Comparison of Power System
Selection of Power System

3

(SED 23103) (Study Planning)
Week 1 6 (Study week)
Week 7 (Practical Test)

Week 8 13 (Study Week)

4

Extra Assessment
Attitude marks
1. Attendant (per/minute = 0.019%)
2. Cheating (per/cheat = 1%)
3. Attire (per/day = 5%)
4. Behavior (per/hour = 5%)

(SRD 23403) - (Assessment)
1. Basic Electrical System
Technical Report 7%
Mini Project 7%
Test 7%
Exam Practical 14%

Technical Report 7%
Mini Project 7%
Test 7%
Exam Practical 14%

Technical Report 6%
Mini Project 6%
Test 6%
Exam Practical 12%

Total Marks (SRD 23403)
Technical Report 7+7+6%
Mini Project 7+7+6%
Test 7+7+6%
Exam Practical 14+14+12%
100%
5

(SRD 23403) - (Content Summary)
Electrical Power
Electrical Control
Electrical Actuator

Pneumatic Power
Pneumatic Control
Pneumatic Actuator

Hydraulic Power
Hydraulic Control
Hydraulic Actuator

End of Course
Comparison of Power System
Selection of Power System

6

Basic Automation System (SRD 23403)
(Study Planning)


Week 11 13 (Study Week)

Extra Assessment
Attitude marks
Attendant (per/minute = 0.019%)
Cheating (per/cheat = 1%)
Attire (per/day = 5%)
Behavior (per/hour = 5%)

7

8

Basic Pneumatic System
9
Objective of Module
Why pneumatic system?
Because: relatively low cost, ease of installation, simple and robust
construction and ready availability in various sizes and stroke lengths. It is a
basic control system. Uses air as its medium. Uses in low and medium
application.

Why learn pneumatic system?
It is a basic control system.

Why learn maintenance of pneumatic system?
To describe the methodology of preventive and corrective maintenance
technique of Pneumatic System.

10
Basic Control System

signal
processing
output
signal
input
pushbutton valve cylinder
11
Control & Maintenance

signal
processing
output
signal
input
Assembly / Maintenance / Troubleshoot
12
Content of Module
CHAPTER 0 SAFETY IN PNEUMATIC SYSTEM
CHAPTER 1 INTRODUCTION TO THE DIDACTIC UNIT
CHAPTER 2 FUNDAMENTAL OF PNEUMATIC
CHAPTER 3 PRODUCTION OF COMPRESSED AIR
CHAPTER 4 DISTRIBUTION OF COMPRESSED AIR
CHAPTER 5 MAINTENANCE UNIT
CHAPTER 6 PNEUMATIC ACTUATOR
CHAPTER 7 VALVES
CHAPTER 8 MAINTENANCE IN PNEUMATIC SYSTEM
CHAPTER 9 ELECTRO PNEUMATIC SYSTEM
CHAPTER 10 MAINTENANCE IN ELECTRO PNEUMATIC SYSTEM

13
Safety in Pneumatic System
chapter 0

To date, no standards exist with regard to the safety of pneumatic systems. Therefore
for all factors affecting safety, reference must be made to existing general
guidelines and regulations from a number of different engineering fields.

Pneumatic systems using several force cylinders must be equipped with an
emergency switch. Based on the design and operating characteristics of a system,
the decision must be made as to whether the EMERGENCY-STOP function is:

to put the system into the zero pressure status
to reset all force cylinders into the initial position, or
to inhibit all cylinders in their current position.

These three options can also be combined.

Precautions must be taken to prevent ACCIDENT.

14

Safety Instructions
Pneumatic workbench is must operated, installed or maintained properly by
students with supervised by lecturer
Pneumatic workbench is used in an application for which it was designed.
The advice of the legal requirements, the safety and the mounting instructions are
must be followed.
Everybody responsible for the installation, operation or maintenance of this unit
must get familiarized with these instructions, especially those relating to safety.
The installation and dismantled of all the components must only be done by
students with supervised by lecturer.
When installing, dismantling or maintaining the unit ensure that the power
(pneumatic / electrical) supply is first disconnected.
Modification of the unit in any form is forbidden without prior consultation with
lecturer.
All safety regulations and all regulations for prevention of accidents in the operating
range are valid.
15
Introduction to Pneumatic System
chapter1
Pneumatic system uses AIR for their working medium.
The air from the atmosphere is reduced in volume by compression.

Advantage of pneumatic system
Availability
Transport
Storage
Temperature
Explosion proof
Cleanliness
Components
Speed
Overload safe
Disadvantage of pneumatic system
Preparation
Compression
Force requirement
Noise level

16
Application Of Pneumatic System
General methods of material handling:
(Clamping, Shifting, Positioning, Orienting, Branching of material flow)

General applications:
Packaging, Filling, Metering, Locking, Driving of axes, Door or chute control,
Transfer of materials, Turning and inverting of parts, Sorting of parts,
Stacking of components, Stamping and embossing of components

17
Pneumatic System Overview

18

Schematic Diagram Of A Pneumatic System
2(A)
1(P)
3(R)
2(A)
1(P)
3(R)
12(Z)
Single Acting
Cylinder
19

Schematic Diagram Of A Pneumatic System
2(B)
4(A)
5(R)
1(P)
3(S)
2(A)
3(R)
1(P)
Double Acting
Cylinder
20
Working Principle
(single acting cylinder)

Retract position Extend position
21
Working Principle
(double acting cylinder)
Retract position Extend position

22
Fundamental of Pneumatic
Chapter 2
1. Physical Quantities
2. Basic Quantities
3. Derived Quantities
4. Characteristic of air
5. Newtons Law
6. Pressure
7. Force

23

Physical Quantity
Air is a mixture of
Nitrogen approx. 78 vol. %
Oxygen approx. 21 vol. %
It also contains traces of carbon dioxide,
argon, hydrogen, neon, helium, krypton
and xenon.

24

Basic Quantity
Basic Unit

Quantity Symbol Units
Length L Meter (m)
Mass m Kilogram (kg)
Time t Second (s)
Temperature T Kelvin (K, 0 C = 273.15 K)

25

Derived Quantity
Derived units

Quantity Symbol Units
Force F Newton (N) = 1 kg m/s
Area A Square meter (m)
Volume V Cubic meter (m)
Flowrate qv (m/s)
Pressure p Pascal (Pa)
1 Pa= 1 N/m

5
1 bar = 10 Pa

26

Characteristic of Air
Air Pressure
Generally, in pneumatics all data concerning air quantity refers to the so-called
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
Figure: Air pressure diagram
27

Boyle-Mariottess Law
Air can be compressed and its tend to expand. The applicable relationship is
given in Boyle-Mariottess Law.

p1 V1 = p2 V2 = p3 V3 = Constant

Air has no particular shape. Its shape changes with the shape of its surroundings.

28

Gay-Lussacs Law
According to the Gay-Lussacs law, the volume of a given mass of gas is
proportional to the absolute temperature as long as the pressure does not
change.
Where:
V1 = Volume at T1, V2 = Volume at T2

29

Newton Law
Newtons Law: Force = mass acceleration

F = m a

where a is replaced by the acceleration due to gravity
g = 9.81 m/s

30
Force
A force is a push or pull
upon an object resulting
from the object's
interaction with another
object. Whenever there is
an interaction between two
objects, there is a force
upon each of the objects.
When the interaction
ceases, the two objects no
longer experience the
force. Forces only exist as
a result of an interaction.

F = m a
31

Pressure

Pressure: 1 Pascal is equal to the constant pressure on
a surface area of 1 m with the vertical force
of 1 N (Newton).

32
Pressure

Pressure (symbol: p) is
the force per unit area
acting on a surface in a
direction perpendicular to
that surface.
Mathematically:

where:

A
p
F
Area of double
acting cylinder
= (d/2)
Assignment 1
AP1: Fundamental in Pneumatic
1. Find F1 if D1 is 32mm and p is 4bar.
2. Find the area if the pressure is 0.5MPa and the force acting at F1 is 200N
3. Find the pressure if force acting at F1 is 30kg and the bore diameter D1 of
the cylinder is 3.0cm
4. Find F1 and F2 if D2 is 22mm, D1 is 32mm and the p is 6 x 10
5
Pa.

(Force in N, Area in mm and Pressure in bar)

33

p
F1
D1
F2
p
D2
34

Production of Compressed Air
Chapter 3
For the continuous performance of control systems and working elements the air
supply should:

At the required pressure,
Dry,
Clean
If these conditions are not fulfilled, then problem of the system will occur. The effect
is downtime on the machinery in addition to increased costs for repair or replacement
of parts.

The equipment to be considered in the generation and preparation of air:

- Inlet filter
- Air compressor
- Air reservoir
- Air dryer
- Air filter with water separator
- Pressure regulator
- Air lubricator as required
- Drainage points
35

Air Compressor
36

Air Compressor
The selection from the various types of
compressors available is dependent upon
quantity of air, pressure, quality and
cleanliness and how dry the air should be.

3 main type of Air Compressor
1. Reciprocating Compressor
2. Centrifugal Compressor
3. Rotary compressor

37

Reciprocating Piston Compressor
The compressed air is drawn thru an inlet valve then the air is
passed on thru an outlet valve via reciprocating piston .
Single stage
piston compressor
Double stage
piston compressor
Diaphragm
piston compressor
38

Working Principle
(single stage piston)
At the end of the stroke, the
piston moves upward, the inlet
valve closes as the air is
compressed, forcing the outlet
valve open to discharge air into
air reservoir.
Air reservoir
Downward movement of the
piston increases volume to
create a lower pressure than
that of atmosphere, causing air
to enter the cylinder through
the inlet valve.
atmosphere
Working Principle
(single stage piston)
Piston travel downward
Compression Chamber is at low pressure state (vacuum)
Inlet valve open, atmospheric pressure will be sucked
into the compression chamber
Piston travel upward
Compression Chamber is at high pressure state
(compressed air)
Outlet valve open, the compressed air will be pushed out
from the compression chamber.
39

40

Working Principle
atmosphere
compression
Compress
Air (3bar)
Inter-cooling
Compress
Air (7bar)
atmosphere
Compress
air
Double stage
piston compressor
Diaphragm
piston compressor
compression
41

Centrifugal & Rotary compressor
Sliding Vane
compressor
Screw
compressor
The rotary compressors use rotating elements to compress and
increase the pressure of the air. During the compression process,
the compression chamber is continually reduced.
42

Working Principle
Sliding Vane
compressor
Screw
compressor
compression
Compress
Air
OUT
Atmosphere
IN
Assignment 2
- AP2: Pneumatic Compressor
43

Working operation on:
1. Single Stage piston compressor,
2. Double Stage piston compressor,
3. Diaphragm piston compressor,
4. Single Chamber Vane compressor,
5. Double Chamber Vane compressor,
6. Screw compressor
44

Air Reservoir
A reservoir is configured to:
Stabilize compressed air.
Compensates the pressure fluctuations.
Air storage for continuous air supply. This has the advantage that the
compressor does not need to operate continuously.
Cooling system for the compressed air.
45

Air Dryer
Is used to eliminate Condensate (water) enters into
Pneumatic System through compressed air.
Water causes problems related to corrosion and seal
wear.
3 type of dryer:
Low temperature drying
Adsorption drying
Absorption drying
46

Low Temperature Drying
The air entering into the refrigeration dryer is
pre-cooled in a heat exchanger by the
escaping cold air. It is then cooled in the
cooling unit to temperatures between + 2 and
+ 5 C. The dried compressed air is filtered.

Before the compressed air is output into the
network, the air is heated to bring the air
back to ambient conditions.
47

Adsorption Drying
Adsorption: water is deposited on the surface
of solids.

The drying agent is a granular material (gel)
consisting almost entirely of silicon dioxide.
Usually two tanks are used. When the gel in
one tank is saturated, the air flow is switched
to the dry, second tank and the first tank is
regenerated by hot-air drying.

The lowest equivalent dew points (down to
90 C) can be achieved by means of
adsorption drying.
48

Absorption Drying
Absorption: A solid or liquid substance
bonds a gaseous substance.

Absorption drying is a purely chemical
process. Absorption drying is not of
major significance in present-day
practice, since the operating costs are
too high and the efficiency too low for
most applications.
49

Distribution of compressed air
Chapter 4

In order to ensure reliable and trouble-free air distribution, a number
of points must be observed. This includes primarily the correct sizing
of the pipe system, but also the pipe material, flow resistances, pipe
layout and maintenance.
Pressure fluctuations in the network make it necessary to ensure
that the pipes are mounted securely in order to avoid leakages at
screwed and brazed connections.

Two type of piping distribution layout:
Dead End Line
Ring
50

Piping Layout
(Dead End Line piping Layout)
Pipe layout is the critical factor
in determining the economic
operation of the compressed-
air system. Compressed air is
fed into the system at intervals
by the compressor. It is often
the case that consumption at
consuming devices rises for
only a short time. This may
lead to unfavorable conditions
in the compressed-air network.
51

Piping Layout
(Ring piping Layout)
Therefore it is
recommended that the
compressed-air network
should be produced in the
form of a ring main. A ring
main ensures largely
constant pressure
conditions.
52

Piping Layout
(Ring piping Layout)
For ease of maintenance, repair or extension of the network without
interfering with the overall air supply, it is advisable to sub-divide the
network into individual sections. Branches with T-pieces and
manifolds with plug-in couplings make this possible. It is advisable
to fit the branch lines with standard ball valves or shut off valves.

53

Piping Installation
Despite the best water separation in the pressure generating system, pressure drops
and external cooling may produce condensate in the pipe system. In order to
discharge this condensate, the pipes should be inclined 1-2%; this can also be
carried out in stages. The condensate can then be discharged from the system via
water separators at the lowest point.

54

Maintenance Unit
Chapter 5
The individual functions of compressed air preparation, i.e. filtering,
regulating and lubricating, can be fulfilled by individual components.
These functions have often been combined into one unit, i.e. the
service unit.
The air service unit is a combination of the following :
Compressed air filter (with water separator)
Compressed air regulator
Compressed air lubricator

55

Maintenance Unit: Component
Air filter:
The compressed air filter has the job of removing all contaminants from the compressed air
flowing through it as well as water which has already condensed.

Air regulator:
The purpose of the regulator is to keep the
operating pressure of the system (secondary
pressure) virtually constant regardless of
fluctuations in the line pressure (primary
pressure) and the air consumption.

Air lubricator:
The purpose of the lubricator is to deliver
a metered quantity of oil mist into a leg of
the air distribution system when
necessary for the operation of the
pneumatic system.

56

Maintenance Unit: Working
Operation
filter regulator lubricator
57
There are two basic types of Pneumatic actuator:
Rotary actuator
(motor / rotary)

Linear actuator
(cylinder)

Pneumatic Actuator
Chapter 6
58

Type of Linear Actuator
Symbol
Single-acting
cylinder
Basic Construction Type
Double-acting
cylinder
Double-acting
cylinder with
end position
cushioning

59

Type of Linear Actuator
Symbol
Tandem
double-acting
cylinder
Cylinders with
through
piston rod
Multiposition
cylinders
60

Rotary Actuator
Symbol
Rotary
cylinders
61
Valve
Chapter 7
Directional Control Valve
Directional control valves are components which change, open or close flow paths in
pneumatic systems. They are used to control the direction of motion of power
components and the manner in which these stop. Directional control valves are
shown as defined in DIN ISO 1219.
Type
2/2-way valve
3/2-way valve
4/2-way valve
5/2-way valve
5/3-way valve

62

Symbols for directional
control valves

The following rules apply to the representation of directional control valves:
Each different switching position is shown by a square.
Flow directions are indicated by arrows.
Blocked ports are shown by horizontal lines.
Ports are shown in the appropriate flow direction with line arrows.
63

Type of Distribution Valve (symbol)
64

Method of Actuation

65

Method of Actuation

66

Port Designation
A numbering system is used to designate directional control valves and is in
accordance with DIN ISO 5599-3. Prior to this a lettering system was utilized and
both systems of designation are presented here:

67

Working Principle
3/2 Way Valve (Normally Close)
68

Working Principle
3/2 Way Valve (Normally Open)

69

Working Principle
3/2 Way Valve (Normally Close)
70

Basic Construction
4/2 Way Valve
71

Basic Construction
5/2 Way Valve (Double Air Pilot)
72

Basic Construction
5/3 Way Valve (Double Air Pilot)
73

Non Return Valve
74

Check Valve
Check valves can stop the flow completely in one direction. In the opposite
direction the flow is free with a minimal pressure drop due to the resistance
of the valve.
75

Shuttle Valve
X Y A
0 0 0
0 1 1
1 0 1
1 1 1
TRUTH TABLE
76

Dual Pressure Valve
X Y A
0 0 0
0 1 0
1 0 0
1 1 1
TRUTH TABLE
77

Quick Exhaust Valve
78

Flow Valve
Introduction
Flow control valves are used to reduce the speed of a cylinder or a motor.

Type of control valve:
2. Throttle Valve
(two way flow control valve)
- Restrict both direction of flow.

1. One Way Flow Control Valve
- Restrict one direction of flow only.
79

Working Principle
One-way flow control valve
The one-way flow control valve where the restrictor is only effective in one direction is a
combination of a restrictor and a non-return valve. The restrictor controls the flow rate in a
single direction dependent on flow. In the opposite direction, the full cross-sectional flow is
released and the return flow is at full pump delivery. This enables the one-way flow control
valve to operate.
80

Working Principle
Throttle Valve
Flow control valves
influence the
volumetric flow of the
fluid in both directions.
Control flow in both direction
81

Combination Valve
1. Pressure sequence valve

2. Time Delay Valve
(Pneumatic Timer)

82

Pressure sequence valve
The principle on which this valve acts is the
same as for the pressure limiting valve. If the
pressure exceeds that set on the spring, the
valve opens.

The flow from 1 to 2 is closed. Outlet 2 is
opened only if a preset pressure has built up
in pilot line 12. A pilot spool opens the
passage 1 to 2.

83

Circuit Example
84

Time delay valve
The time delay valve is a
combined 3/2-way valve, one
way flow control valve and air
reservoir. The 3/2-way valve can
be a valve with normal position
open or closed. The delay time is
generally 0-30 seconds for both
types of valves.

85

Circuit Example
86

Pneumatic Counter
c
a.z
b.y
1(P) 3(R)
2(A)
87

Circuit Example
Assignment 3
88

1. P1 AND P2 OR P3 Cyl. A ext
2. (P1 OR P2) AND (P3 OR P4) Cyl. A ext
3. (P1 AND P2) OR P3 OR P4 Cyl. A ext
4. (P1 AND P2 AND P3) OR P4 Cyl. A ext

Assignment 4
89

1. P1 AND P2 OR P3 Cyl. A ext
P4 Cyl. A ret
2. (P1 AND P2) Cyl. A ext
(P23 OR P4) Cyl. A ret
3. (P1 OR P2) AND P3 Cyl. A ext
(P4 AND P5) OR P6 Cyl. A ret

Assignment 5 & Assignment 6
slow slow fast
1. A+ B+ A- B-

fast slow slow
2. A+ B+ C+ A- B- C-
slow slow
3. A+ B+ A- C-
C+ B-

1. A+ A- B+ B-

2. A+ B+ B- A-

90

91
Maintenance
Chapter 8
Systematic maintenance helps to extend service life and improve the
functional reliability of pneumatic control systems.
A detailed maintenance plan should be drawn up for every pneumatic
system. A maintenance plan lists the maintenance tasks and time intervals.
In the case of complex control systems, the maintenance documentation
must include a function diagram and circuit diagram.
The time intervals between individual maintenance work to be carried out is
dependent on the period of use, the wear characteristics of the individual
components and the ambient medium. The following maintenance work
must be carried out frequently and at short intervals:
Service unit
Check the filter
Drain water regularly
Refill and set lubricator, if a lubricator is used.
Check signal generators for possible deposits of dirt or scarf

92
Maintenance Procedure

The following maintenance work can be undertaken at
greater time intervals:

Check the seals of the connectors for leaks
Replace lines connected to moving parts
Check the rod bearings in the cylinders for wear and replace if
necessary
Clean or replace filter elements
Check function of safety valves
Check mountings
93

Control system development
(design procedure)
The methods of representing the control problem include:

1. Positional sketch
2. Displacement-step diagram
3. Control chart
4. Function diagram
5. Function chart
6. Circuit diagram

Positional sketch
Displacement-step diagram
1
2
94

Displacement-time diagram
Control chart
Function diagram
Function
chart
2
3
4
5
95

Circuit diagram
6
96
Electro-Pneumatic System
Chapter 9

MSI Electro-Pneumatic System
Fathul Hazrimy Ahmad
Assistant Lecturer
Pneumatic Hydraulic Department
97

Schematic
Design Of An
Electro-
Pneumatic
System
98


Change
of
Switching
control

Y1
2(A)
1(P) 3(R)
P1
2(A)
1(P) 3(R)
Conventional Pneumatic
Electro-Pneumatic
99

Conventional vs. Electro
100

Hydraulic Pump
Control
Valve
Cylinder
Power
Supply
Pushbutton
Relay,
Timer,
Solenoid
Electro-Pneumatic Overview
From electro
101

1. Safety precaution
2. Introduction
3. Advantages
4. Comparison
5. Electrical Fundamental
6. Electrical Input Element
7. Sensor
8. Relay
9. Solenoid
10. Electrical Timer
11. Sequence Control
102
Safety Precaution

1. Pneumatic safety must be apply
2. DO NOT wear sandals, wear covered shoes
3. DO NOT wear excessive jewelry
4. DO NOT wear swing-loose-long hair style, neatly tie-up the long hair or
place under a proper head gear.
5. DO NOT wear shoes with heel higher than 1" (2.5 cm)
6. DO wear lab-coat all the time
7. DO NOT disturb people who are conducting experiments! (or any time)
8. NO eating or drinking inside the lab.
9. NO social gathering is allowed in the labs. The labs should not be
crowded for non-working purposes.
10. In case of spilling water on a lab bench near power points, first SWITCH
OFF the electrical power before cleaning.
11. TO INSPECT any electrical equipment, first turn the power off and ask for
the instruction/help from the lab officer in charge. Any faulty equipment
should be attended by trained personnel only. DO NOT do it on your
own.
103
Introduction
Electro-Pneumatic Systems are made up of
pneumatic and electrical components:

The movements are generated by Pneumatic means
(e.g. by cylinders).

Signal input and signal processing, on the other hand,
are effected by Electrical and Electronic
components (e.g. electromechanical switching
elements or stored-program controls).

104
Advantages

Electrical signals can be transmitted via cables quickly and easily
and over great distances. Mechanical signal transmission
(linkages, cable-pulls) or pneumatic signal transmission (tubes,
pipes) are far more complex.

In the field of automation, signal processing is generally effected
by electrical means. This enhances the options for the use of
electro-pneumatic systems in automatic production operations (e.g.
in a fully automatic pressing line for the manufacture of car wings).

Many machines require complex control procedures (e.g. plastics
processing). In such cases, an electrical control is often less
complex and more economical than a mechanical or pneumatic
control system.
105

Comparison
106

Electrical Fundamental
The relationship between voltage, current strength and resistance
is described by Ohms law. Ohms law states that in a circuit with
constant resistance the current strength changes in proportion to the
change in voltage:

if the voltage increases, the current strength also increases.
if the voltage falls, the current strength also decreases.
107

In the field of mechanical engineering, power can be defined in
terms of the work performed. The faster a task is performed, the
greater the required power. Power therefore means work per unit
of time.
In the case of a consuming device in a circuit, electrical energy is
converted into kinetic energy (e.g. electrical motor), light radiation
(e.g. electrical lamp) or thermal energy (e.g. electrical heater,
electrical lamp). The faster the energy is converted, the greater the
electrical power.
Electrical power
108

A power supply unit consists of the
following modules:
the mains transformer which
transforms the alternating voltage of
the mains supply (e.g. 220 V) into
the output voltage (mostly 24 V).
a smoothed direct voltage is
generated by the rectifier G and the
capacitor C.
the direct voltage is then stabilized
by the in-phase regulator.
Power Supply
109

Electrical controls are generally supplied with a direct current of 24V.
The alternating voltage from the power supply therefore has to be
stepped down to 24V and then rectified.

Conversion AC to DC
AC DC
110

Electrical input elements
FUNCTION OF SWITCH:
To open or close the flow of current to the consuming device.
TYPE:
1. "pushbutton switches" (push-buttons), and
2. "control switches".
CONTROL SWITCH:
In control switches, the two switching positions are mechanically interlocked. A switching
position is maintained until the switch is activated once again.
PUSH-BUTTON:
A push-button only opens or closes a current circuit for a short time. The selected switching
position is only active while the push-button is pressed.

Both switch types are available for operation with normally closed contacts, normally open contacts or
changeover contacts.

BASIC TYPE OF SWITCH:
1. Normally open contact
2. Normally closed contact
3. Changeover switch
111

Pushbutton (normally Open)
Circuit is open when the push-button is in the normal position

Pressed S1, H will on
Circuit Example:
112

Pushbutton (normally Close)
Circuit is closed when the push-button is in the normal position

Pressed S1, H will off
Circuit Example:
113

Changeover Switch
These contacts combine the functions of normally closed and normally
open contacts in one unit.

Pressed S1, H2 will on,
Release S1, H1 will on.
Circuit Example:
114

Switching Signal
And
Function
Or
Function
And
Function
Or
Function
Switching ON Command
Switching OFF Command
S1 AND S2 H1 on S1 OR S2 H1 on S1 AND S2 H1 off S1 OR S2 H1 off
115

Assignment 7
1. Press S1 AND S2 H1 ON
2. Press S1 OR S2 H1 ON
3. Press S1 AND S2 AND S3 H1 ON
4. Press S1 OR S2 OR S3 H1 ON
5. Press (S1 AND S2) OR S3 H1 ON
6. Press (S1 OR S2) AND S3 H1 ON
7. Press (S1 OR S2) AND (S3 OR S4) H1 ON
8. Press (S1 AND S2) OR (S3 AND S4) H1 ON
9. Press (S1 AND S2 AND S3) OR S4 OR S5 H1 ON
10. Press [(S1 OR S2) AND S3] OR [(S4 OR S5) AND S6] H1 ON

116

24v
0v
S1
L1
S2
Installation Example #1 (Series)
11 12
23 24
31 32
43 44
H1
H2
H3
H1
H2
H3
11 12
23 24
31 32
43 44
11 12
23 24
31 32
43 44
11 12
23 24
31 32
43 44
0V
24V
117

Practical
2. Press S1 OR S2 H1 ON
4. Press S1 OR S2 OR S3 H1 ON
6. Press (S1 OR S2) AND S3 H1 ON
8. Press (S1 AND S2) OR (S3 AND S4) H1 ON
10. Press [(S1 OR S2) AND S3] OR [(S4 OR S5) AND S6] H1 ON

118

Sensor
Any device that receives a signal (e.g. heat or
pressure or light or motion etc.) and responds
to it in a unique manner [synonym: detector]
119

Limit switch
A mechanical limit switch is an
electrical switch which is activated
when a machine part or a workpiece
is in a certain position.
Normally open limit switch
1-4
Normally closed limit switch
1-2
120

Pressure switch
requires a pressure to
activated the sensor
Normally open limit switch
1-4
Normally closed limit switch
1-2
121

Practical
(Sensor)
Roller
Limit
Switch
1.
2. Pressure
Sensor
a.
b.
a.
b.
122

Proximity Sensor
Proximity sensors is refer to Non-contacting sensors

Type of Proximity Sensor

1. Reed switch -
2. Inductive sensor
3. Capacitive sensor -
4. Optical / Photo Sensor -
123

Reed Switch
(magnetic sensor)
124

Inductive Proximity Sensor
(sense materials with good electrical conductivity)
125

Capacitive Proximity Sensor
(sense all kind of material)
126

Optical/Photo Proximity sensor
(sense reflected light)
Three type:
through-beam sensors
retro-reflective sensors
diffuse sensors

127

Optical Through-beam
Proximity sensor
128

Optical Retro-reflective
Proximity sensor
129

Optical Diffuse
Proximity sensor
130

Circuit Example
Proximity 2 wire
Proximity 3 wire PNP
Proximity 3 wire NPN
131

Practical
(Sensor)
1. 2. 3.
Reed
Switch
(Proximity
Magnetic
Sensor)
4.
Proximity
Inductive
Sensor
Proximity
Capacitive
Sensor
Proximity
Optical
Sensor
132

Relay
Relays are electromagnetically
actuated switches.
They consist of a housing with
electromagnet and movable
contacts.
An electromagnetic field is created
when a voltage is applied to the coil
of the electromagnet.
This results in attraction of the
movable armature to the coil core.
The armature actuates the contact
assembly.
This contact assembly can open or
close a specific number of contacts
by mechanical means.
If the flow of current through the coil
is interrupted, a spring returns the
armature to its original position.

133

Concept of a Relay
(Electromagnet)
An electromagnet is a type of magnet in which the
magnetic field is produced by the flow of an electric
current. The magnetic field disappears when the current
ceases.
134

Working Principle
Relay
1 pole
Relay
2 pole
135

Circuit Example
Direct Control
In-direct Control
136

Practical
(Relay)
S1 H1 on
S1 H1 on, H2 off, H3 on, H4 off
S1 H1 on
S2 H2 off
1.
2.
3.
137

Assignment 8
Press S3 OR S4 H1 OFF
Press S4 OR S5 OR S6 H1 OFF
Press (S4 OR S5) AND S6 H1 OFF
Press (S5 AND S6) OR (S7 AND S8) H1 OFF
Press [(S6 OR S7) AND S8] OR [(S9 OR S10) AND S11] H1 OFF

138

Practical
Press S3 OR S4 H1 OFF
Press S4 OR S5 OR S6 H1 OFF
Press (S4 OR S5) AND S6 H1 OFF

139

Solenoids
In electro-hydraulics, valves are actuated via solenoids. It has the
same concept of electromagnet.

solenoid
Directional control Valve
140

Electrical Construction of Solenoid
141

Electro-Pneumatic Circuit Diagram
P
n
e
u
m
a
t
i
c

C
i
r
c
u
i
t

C
o
n
t
r
o
l

C
i
r
c
u
i
t

142

Assignment 9
1. Press S1 AND S2 Cly. A ext
2. Press S1 OR S2 Cly. A ext
3. Press S1 AND S2 AND S3 Cly. A ext
4. Press S1 OR S2 OR S3 Cly. A ext
5. Press (S1 AND S2) OR S3 Cly. A ext
6. Press (S1 OR S2) AND S3 Cly. A ext
7. Press (S1 OR S2) AND (S3 OR S4) Cly. A ext
8. Press (S1 AND S2) OR (S3 AND S4) Cly. A ext
9. Press (S1 AND S2 AND S3) OR S4 OR S5 Cly. A ext
10. Press [(S1 OR S2) AND S3] OR [(S4 OR S5) AND S6] Cly. A ext

143

Assignment 10
Press S3 OR S4 Cly. A ret
Press S4 OR S5 OR S6 Cly. A ret
Press (S4 OR S5) AND S6 Cly. A ret
4. Press (S1 OR S2) AND (S3 OR S4) Cly. A ext
Press (S5 AND S6) OR (S7 AND S8) Cly. A ret
5. Press (S1 AND S2 AND S3) OR S4 OR S5 Cly. A ext
Press [(S6 OR S7) AND S8] OR [(S9 OR S10) AND S11] Cly. A ret

144

Practical
Press S3 OR S4 Cly. A ret
Press S4 OR S5 OR S6 Cly. A ret
Press (S4 OR S5) AND S6 Cly. A ret

145

11. Sequence Control
Single cycle (SC)
In a single cycle mode, the sequence will run only in one cycle
via pushing a pushbutton.
Example: A+ A-

Continuous cycle (CC)
In a continuous cycle mode, the sequence will run continuous
when start button is pressed, the sequence will stop until stop
button is pressed.
Example: A+ A- A+ A- A+ A- . Until stop is pressed
146

Assignment 11
1. A+ B+ A- B-

2. A+ B+ C+ A- B- C-

3. A+ A-
B+ B-

4. A+ B+ A- C-
A- B+

147


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