Chapter 4

Module 4: Components of a pneumatic system

Table of Contents
Components of a Pneumatics system ........................................................................................... 4-2
 Valves ................................................................................................................................. 4-2
 Directional control valves .................................................................................................. 4-6
 Non-return valves .............................................................................................................. 4-7
 Flow control valves ............................................................................................................ 4-7
 Pressure control valves ...................................................................................................... 4-7
 Combination valves ............................................................................................................ 4-8
 Power components ............................................................................................................ 4-8

Reference ......................................................................................................................................... 4-

Table of Figure
Figure 1: Components of a Pneumatics system _______________________________________________________ 4-2
Figure 2: Control of a single acting cylinder __________________________________________________________ 4-3
Figure 3: Control of a double acting cylinder _________________________________________________________ 4-4
Figure 4: 3/2 way DCV ___________________________________________________________________________ 4-5
Figure 5: 5/2 way DCV ___________________________________________________________________________ 4-5
Figure 6: Directional Control Valve _________________________________________________________________ 4-6
Figure 7: Nom Return Valve ______________________________________________________________________ 4-6
Figure 8: Flow Control Valve ______________________________________________________________________ 4-7
Figure 9: Pressure Control Valve ___________________________________________________________________ 4-7
Figure 10: Shuttle and Dual-pressure valve __________________________________________________________ 4-8
Figure 11: Pneumatic cylinder_____________________________________________________________________ 4-9
Figure 12: Single acting cylinder __________________________________________________________________ 4-10
Figure 13: Double acting cylinder _________________________________________________________________ 4-10

What you will cover

Module 4: Components of a pneumatics system
Directional control valves
Non-return valves
Flow control valves
Pressure control valves
Combination valves
Power components

Learning Outcome
At the end of this module participants will be able to:
Understand the working of pneumatic valves and actuators
Identify pneumatic valves and actuators

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 Module 4: Components of a pneumatics system

Components of a Pneumatics system

Pneumatic systems consist of an interconnection of different group of element as stated in module

one.

Figure 1: Components of a Pneumatics system

The energy supply element has been discussed in module two (Compressor, reservoir, pressure
regulating valve and the service unit).

In this module, other elements will be discussed in detail. Others includes:

 Signal Inputs
 Signal processing
 Signal output
 Command execution

Valves

The function of valves is to control the pressure or flow rate of pressure media. Depending on
design, these can be divided into the following categories:

 Directional control valves

 Input/signalling elements
 Processing elements
 Control elements
 Non-return valves
 Flow control valves
 Pressure control valves

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 Module 4: Components of a pneumatics system

 Shut-off valves
The directional control valve controls the passage of air signals by generating, cancelling or
redirecting signals.
The valve is described by:
 Number of ports or openings (ways): 2-way, 3-way, 4-way, etc.
 Number of positions: 2 positions, 3 positions, etc.
 Methods of actuation of the valve:
 manually actuated,
 mechanically actuated,
 pneumatically actuated,
 electrically actuated.
 Methods of return actuation: Spring return, air return, etc.

Valve operation
Generally, the actuation of a cylinder is effected via a directional control valve. The choice of such
a directional control valve (number of connections, number of switching positions, and type of
actuation) is dependent on the respective application.

Control circuit for the single-acting cylinder

The piston rod of a single-acting cylinder is to advance when a push button is operated. When the
push button is released, the piston is to automatically return to the initial position.

A 3/2-way valve controls the single-acting cylinder. The valve switches from the initial position
into the flow position, when the push-button actuator is pressed. The circuit includes the following
primary features:

 Single-acting cylinder, spring return

 3/2-way directional control valve: push button for operation and spring for return force
 Supply air source connected to the 3/2-way valve
 Air connection between valve and cylinder

Figure 2: Control of a single acting cylinder

The 3/2-way control valve has 3 ports. The supply port, the exhaust port and the outlet port. The
relationship between these ports is determined by the passages through the valve. The possible
switching positions are shown in the above illustration.

Initial position:

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The initial position (left-hand circuit) is defined as the "rest' position of the system. All connections
are made and there is no manual intervention by the operator. The air supply is shut off and the
cylinder piston rod retracted (by spring return). In this valve position, the piston chamber of the
cylinder is exhausted.

Push-button operation:
Pressing the push button moves the 3/2-way valve against the valve return spring. The diagram
(right-hand circuit) shows the valve in the actuated or working position. The air supply is now
connected via the valve passage to the single-acting cylinder port. The build-up of pressure causes
the piston rod of the cylinder to extend against the force of the cylinder return spring. As soon as
the piston rod arrives at the forward end position, the air pressure in the cylinder body reaches a
maximum level.

Push-button release: As soon as the push button is released, the valve return spring returns the
valve to its initial position and the cylinder piston red retracts.

Note: The advancing speed and the retracting speed are different because:
 The piston reset spring creates a counteracting force when advancing.
 When retracting, the displaced air escapes via the valve. A flow resistance must therefore
be overcome.
Normally, single-acting cylinders are designed in such a way that the advancing speed is greater
than the retracting speed.

Control circuit for the double-acting cylinder

The piston rod of a double-acting cylinder is to advance when a push button is operated and to
return to the initial position when the push but-ton is released. The double-acting cylinder can
carry out work in both directions of motion, due to the full air supply pressure being available for
extension and retraction.

A 5/2-way directional control valve controls the double-acting cylinder. A signal is generated or
reset on the valve, if a push-button actuator is pressed or released.
The circuit includes:
 Double-acting cylinder
 5/2-way directional control valve: push button for operation and spring for return force
 Supply air source connected to the 5/2-way valve
 Air connections between valve and cylinder

Figure 3: Control of a double acting cylinder

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Initial position: In the initial position (left-hand circuit) all the connections are made and there is
no manual intervention by the operator. In this unactuated position, air is applied at the cylinder
piston rod side, while the pressure on the piston side of the cylinder is exhausted.

Push button operation: Pressing the push button operates the 5/2-way valve against the valve
return spring. The diagram (right-hand circuit) shows the valve in the operated or actuated
position. In this position, the supply pressure is connected to the piston side of the cylinder, while
the piston rod side is exhausted. The pressure on the piston side advances the piston rod. Once
full extension is reached, the air pressure on the piston side reaches a maximum.

Push button release: Once the push button is released, the valve return spring pushes the valve
into the initial position. The supply pressure is now connected to the piston rod side, while the
piston side is exhausted via the exhaust port of the valve. The piston rod retracts.

Note: The advancing speed and the retracting speed are different due to the fact that the cylinder
volume on the piston rod side is smaller than on the piston side. Thus, the amount of supply air
required during retraction is smaller than during extension, and the return stroke is faster.

Valves as signalling, processing and controlling elements

3/2 way single pilot (air actuated), spring return DCV: As a signalling element the directional
control valve is operated for example, by a roller lever to detect the piston rod of a cylinder.

Figure 4: 3/2 way DCV

3/2 way single pilot (air actuated), spring return DCV: As a processing element the directional
control valve redirects or cancels signals depending on the signal inputs received

Figure 5: 5/2 way DCV

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5/2 way double pilot (air actuated), manual override DCV: As a control element the directional
control valve must deliver the required quantity of air to match the power component
requirements.

Directional control valves

Figure 6: Directional Control Valve

Non-return valves

The non-return valve allows a signal to flow through the device in one direction and in the other
direction blocks the flow. Amongst others, this principle is applied in shuttle valves or quick
exhaust valves. The non-return valve in the form of a basic element of other valve types is shown
in a broken outline in the illustration below.

Figure 7: Nom Return Valve

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Flow control valves

The flow control valve restricts or throttles the air in a particular direction to reduce the flow rate
of the air and hence control the signal flow. Ide-ally it should be possible to infinitely vary the
restrictor from fully open to completely closed. The flow control valve should be fitted as close to
the working element as is possible and must be adjusted to match the requirements of the
application. If the flow control valve is fitted with a check valve then the function of flow-control
is unidirectional with full free flow in one direction

Figure 8: Flow Control Valve

Pressure control valves

Pressure control valves are utilised in pneumatic systems. There are three main groups: valves
 Pressure limiting valves
 Pressure regulating valves
 Pressure sequence valves
The pressure limiting valves are utilised on the up-stream side of the compressor to ensure the
receiver pressure is limited, for safety, and that the supply pressure to the system is set to the
correct pressure.
The pressure regulating valve keeps the pressure constant irrespective of any pressure
fluctuations in the system. The valve regulates the pressure via a built-in diaphragm.
The pressure sequence valve is used if a pressure-dependent signal is required for the advancing
of a control system

Figure 9: Pressure Control Valve

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When the applied control signal reaches the set pressure, the 3/2-way valve incorporated at this
point is actuated. Conversely, the valve re-verses, if the control signal falls below the set pressure

Combination valves

The combined functions of various elements can produce a new function. An example is the time
delay valve which is the combination of a one-way flow control valve, a reservoir and a 3/2-way
directional control valve.

Depending on the setting of the throttling screw, a greater or lesser amount of air flows per unit
of time into the air reservoir. When the necessary control pressure has built up, the valve switches
to through flow. This switching position is maintained for as long as the control signal is applied.

Processing elements (processors)

To support the directional control valves at the processing level, there are various elements which
condition the control signals for a task. The elements are:
Dual pressure valve (AND function)
Shuttle valve (OR function)

Figure 10: Shuttle and Dual-pressure valve

A shuttle valve permits the combination of two input signals into an OR function. The OR gate has
two inputs and one output. An output signal is generated, if pressure is applied at one of the two
inputs. The further development of processing elements in pneumatics has brought about the
modular systems, which incorporate directional control valve functions and logic elements to
perform a combined processing task. This reduces size, cost and complexity of the system.

Power components

The power section consists of control elements and power components or actuators. The actuator
group includes various types of linear and rotary actuators of varying size and construction. The
actuators are complemented by the control elements, which transfer the required quantity of air
to drive the actuator. Normally this valve will be directly connected to the main air supply and
fitted close to the actuator to minimise losses due to resistance.

Actuators can be further broken down into groups:

Linear actuators (cylinder)
-Single-acting cylinder
- Double-acting cylinder
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Rotary actuators
- Air motors
- Rotary actuators

Cylinder
A pneumatic cylinder is a mechanical device typically made up of a piston & cylindrical case, that
is ideal for producing powerful linear movement.
 Operated by compressed air through designated air ports on the cylinder
 Adverse conditions can be easily tolerated such as high humidity, dry and dusty
environments.
 The bore of a cylinder determines the maximum force that it can exert.
 The stroke of a cylinder determines the maximum linear movement that it can produce.
 The maximum working pressure depends on the cylinder design.
 Thrust & Speed are controllable through flow regulators.

Figure 11: Pneumatic cylinder

Single-acting cylinder with spring return

 Single acting cylinders have a power stroke in one direction only
 Normally in
 Normally out

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Single acting NO spring return

 Gravity or other external force to return the rod

Figure 12: Single acting cylinder

Double acting cylinders

 Double acting cylinders use compressed air to power both the outstroke and instroke.
 Superior speed control is possible
 There are
 Non-cushioned types
 Fixed cushioned types
 Adjustable cushioned types
 Magnetic Piston types
 Rod through

Figure 13: Double acting cylinder

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Rodless cylinders
 Contain the movement produced within the same overall length taken up by the cylinder body.
 For example, action across a conveyor belt, or for
vertical lifting in spaces with confined headroom.
 Movement is from a carriage running on the side of the
cylinder barrel.
 A slot, the full length of the barrel allows the carriage to
be connected to the piston.
 Long sealing strips on the inside and outside of the
cylinder tube prevent loss of air and ingress of dust.

Rotary Actuator
 Used for turning components, operating process control valves, performing a wrist action
in robotic applications.
 Can provide angular reciprocating rotation up to 360o
 Rotary vane types
 Rack and pinion types

Rotary rack and pinion

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