pneumatic technology
TRANSCRIPT
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ENGINEERING MAKES DIFFERENT 1
Pneumatic Technology
Workbook (Practical)
Version : English
Description : Workbook, fundamental level
VIS MECHATRONIC SDN BHD
PLAZASRI MUDA,
TINGKAT 3,
LOT NO:1,JALAN SETIA 25/65,TAMAN SRI MUDA,SEKSYEN 25,
40400 SHAH ALAM,
SELANGOR DARUL,EHSAN,MALAYSIA.
TEL : (+6)03-5525-1893,
: (+6)03-5124-0839.
FAX :(+6)03-5124-0893.
E-MAIL : [email protected]
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ENGINEERING MAKES DIFFERENT 2
Contents
Section Description Page
A Safety Instruction 3-4
Introduction 5Pneumatic training kit 6Component symbol 7-8
B Exercise 9-29
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Section A Safety Instruction
1.0 Introduction
The pneumatic technology system including the board, components and support
equipments has been selected, designed, manufactured, tested and commissioned incompliance with relevant safety standard. The system will not caused any hazards to theuser or property under standard specification and condition of operation.
The following instruction shall be observed in the interests of the safety during theoperation of the system.
2.0 Qualified Training Instructor
2.1 Trainees shall only allow to use or operating the system in the presence of theinstructor or assigned qualified personnel.
2.2 The instructor shall brief to the trainees all the relevant safety precaution and procedures before the use of the system.
2.3 In case of unsure of the operational safety for particular components, modules,cell or system, always refer or study the relevant technical documentation
carefully.
3.0 Safety Instruction
3.1 Observe general safety regulation
3.2 When carry out the exercise involving air pressure, handle it with extra care andmake sure the attachment to cylinder is safe to use.
4.0 Electrical system
4.1 The user shall use proper tools provided to install or dismantle module,
component or system.
4.2 Install all the components accordance to specification and requirement of thestandard system.
4.3 Ensure all the components are securely attached onto the board.
4.4 When the system is in operation, interventions of the process may cause injuries
or damages to the property.
4.5 Carried out routine maintenance check on component.
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6.0 Operating Air Pressure
6.1 The pressure must be with maximum 4 bar
6.2 The pressure air must be filter by air service unit to avoided any dirty while
running the exercise or project.
6.3 For certain exercise, follow the requirement and procedure in preparing
pneumatic component and air compressor.
6.4 Tubing that able to withstand the air pressure operating pressure as require by the
system.
7.0 Pneumatic connections
7.1 Before starting operating, check all the connection is securely connected and
always ensure the circuit are correct.
7.2 In case of wrong connection of tubing, slowly release the air to reduce the
pressure and change with the correct connection.
7.3 Contact Vis Mechatronic SDN BHD or email us [email protected] for
technical assistance if require.
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1.0 Introduction
The workbook is specifically design according to the syllabus of Pneumatic
Technology, Fundamental level. The fundamental level provides the introductory of pneumatic principles, working and control elements interior design and its functionality
as well as exercises to assists the user gaining practical experiences toward enhancingtheir knowledge on pneumatic technology, particularly important when involve in the realapplication.
Upon completion of fundamental level, the user could study in deep with thefollow-up course such as advanced level which enable the user acquire higher skills in
hydraulic controls.
The pneumatic technology trainer is comprises several modules to offer the most
effective learning in pneumatic technology. The hardware could be integrated withsoftware vis electrical interface and relevant module.
All the pneumatic training equipment is using identical structures as show below
Hardware Teachware Software
The hardware selected is industrial grade that provides user to getting used inindustrial environment. The hardware is integrated with input device and other
accessories, if any to adapt it for training purposes.
The courseware is presented in several formats, such as printed, multimedia or oral.
The standard courseware include:
Textbook according to syllabus Workbook according to syllabus Pneumatic symbol
Standard operation procedures (SOP)
The pneumatic training system uses FluidSIM (festo) as its simulation software
package to enhancing the effectiveness of the learning program.It is a very useful andindispensable software tool that suit for the engineering, maintenance and educational
application.
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2.0 Pneumatic training kit
The training kit is designed and construct using pneumatic component. The pneumatic
system are power system using air compressor as a working medium for the power transmission.
2.0.1 Objective
At the end of the training student must be able to:
1. Identify the function of pneumatic component and their symbol2. Design the pneumatic circuit
3. Run test circuit and troubleshoot
Figure 2.0 : Pneumatic training kit
2.1 Pneumatic bill of material (BOM)
No Component Description Quantity
1 3/2 way valve push button actuation spring return 3
2 5/2 way valve air actuation spring return 1
3 5.2 way valve air actuation air return 2
4 3/2 way limit valve switch actuation spring return 4
5 OR GATE 1
6 Double acting cylinder 2
7 Cylinder bracket 2
8 L connector (4mm) 29
9 Silencer/ filter 6
10 Air flow control (control) 4
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2.2 Component symbols
No Symbol Component
1Double Acting cylinder
2
3/2 way valveroller limit switch actuation
spring return
3
5/2 way valve
Air actuationspring return
4
5/2 way valveair actuation
air return
5 Compressor
6
3/2 way valve
Push button actuationspring return
7 Shuttle valve
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No Symbol Component
8 Air filter
9 Pressure regulator
10 Pressure gauge
11
Air service unit
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Section B
Exercise
Exercise no Exercise Description Page
1 Using the pneumatic component such as 3/2 way valve
push button actuation spring return and 5/2 way valve 10-11air actuation spring return to active the double acting
cylinder.2 Using the pneumatic component such as 3/2 way valve
push button actuation spring return and 5/2 way valve 12-13
air actuation air return to active the double actingcylinder.
3 Using the pneumatic component such as 3/2 wayvalve push button actuation spring return and 5/2 wayvalve air actuation air return to active 2 cylinder. 14-15
4 Using the pneumatic component such as 5/2 way
valve air actuation spring return, 5/2 way valve air actuation air return and 3/2 way valve push button
actuation spring return to active 2 cylinder.16-17
5 Using the pneumatic component such as OR gate to
active the cylinder. 18-196 Using the pneumatic component such as roller limit
switch to active the cylinder 20-21
7 Using the pneumatic component such as 3/2 wayvalve, 5/2 way valve and roller limit switch to active
the cylinder. 22-23
8 Using a pneumatic component such as limit switch toactivate the oscillation system. 24-25
9 Using a push button to control the oscillation system
until press push button 2 the system will stop. 26-2710 Understand the function and sequence of A+ B+
A- B- 28-29
Note : Vis Mechatronic Sdn. Bhd. Reserve a right to add, delete or amend the exercise
and solutions content without prior notice
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Exercise 1 : Press push button, cylinder extend. When release push button cylinder willretract
Description
This exercise is to introduce the function of the 5/2 way valve air actuation, spring returnand 3/2 way valve push button actuation spring return in the pneumatic system. The test
circuit is to show how the air pressure flow through the pneumatic component and learn
the characteristic of the pneumatic component. The user require to observing the functionand the condition of circuit.
Precaution
The trainee shall read the respective component data sheet in order to understand thecharacteristic and performance of the individual component before carryout experiment.
Always check the pneumatic compressor and the connection of circuit before test and run.Refer to safety precaution section for further details to avoid hazards.
Component list
No Component Quantity
1 3/2 way valve push button actuation spring return 1
2 5/2 way valve air actuation spring return 1
3 Double acting cylinder 1
4 Air service unit 1
5 Compressor 1
Note: The pneumatic tubing is require in the system in order to connecting the componentsassembly circuit, the length of the tubing uses is subject to the position of the
component.
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Exercise 1 solution
Following constructed circuit diagram show the function 5/2 way valve air actuation,
spring return and 3/2 way valve push button actuation spring return.
Circuit diagram 1
The circuit 1 is to determine the cylinder extend and return by using the valve connected
at pneumatic training kit.
Double acting cylinder
3/2 way valve
push button actuation
spring return
5/2 way valve
Air actuationspring return
Air service unit
Compressor
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Exercise 2 Press push button 1 cylinder extend, then press push button 2 cylinder willretract
Description
This exercise is to introduce the function of the 5/2 way valve air actuation, air return inthe pneumatic system. The test circuit is to show how the air pressure flow through the pneumatic component and learn the characteristic of the pneumatic component. The user
require to observing the function and the condition of circuit.
Precaution
The trainee shall read the respective component data sheet in order to understand the
characteristic and performance of the individual component before carryout experiment.
Always check the pneumatic compressor and the connection of circuit before test and run.Refer to safety precaution section for further details to avoid hazards.
Component list
No Component Quantity
1 3/2 way valve push button actuation spring return 2
2 5/2 way valve air actuation air return 1
3 Double acting cylinder 1
4 Air service unit 1
5 Compressor 1
Note: The pneumatic tubing is require in the system in order to connecting the componentsassembly circuit, the length of the tubing uses is subject to the position of the
component.
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Exercise 2 solution
Following constructed circuit diagram show the function 5/2 way valve air actuation, air
return.
Circuit diagram 2
The circuit 2 is to determine the cylinder extend and return by using the valve connected
at pneumatic training kit.
Double acting cylinder
3/2 way valve
push button actuation
spring return
3/2 way valve
push button actuation
spring return
Air service unit
Compressor
5/2 way valve
Air actuation
air return
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Exercise 3 Press push button 1 cylinder 1 extend, press push button 2 cylinder 2 extend.
Description
This exercise is to learn the function of the valve and cylinder in the pneumatic system.
The test circuit is to show how the air pressure flow through the pneumatic componentand learn the characteristic of the pneumatic component. The user require to observingthe function and the condition of circuit.
Precaution
The trainee shall read the respective component data sheet in order to understand thecharacteristic and performance of the individual component before carryout experiment.
Always check the pneumatic compressor and the connection of circuit before test and run.
Refer to safety precaution section for further details to avoid hazards.
Component list
No Component Quantity
1 3/2 way valve push button actuation spring return 2
2 5/2 way valve air actuation air return 2
3 Double acting cylinder 2
4 Air service unit 1
5 Compressor 1
Note: The pneumatic tubing is require in the system in order to connecting the components
assembly circuit, the length of the tubing uses is subject to the position of thecomponent.
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Exercise 3 solution
Following constructed circuit diagram show the function with two cylinder, two valve
and start push button
Circuit diagram 3
Double acting cylinder 1 Double acting cylinder 2
5/2 way valve
Air actuation
air return 1 5/2 way valve
Air actuation
air return 2
3/2 way valve
push button actuation
spring return 1
3/2 way valve
push button
actuation spring
return 2
Air service unit
Com ressor
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Exercise 4 Press push button 1 cylinder 1 extend, release push button 1 cylinder 1retract. Press push button 2 cylinder 2 extend, press push button 3 cylinder 2
retract
Description
This exercise is to learn the function of combination the valve and cylinder in the pneumatic system. The test circuit is to show how the air pressure flow through the
pneumatic component and learn the characteristic of the pneumatic component. The user
require to observing the function and the condition of circuit.
Precaution
The trainee shall read the respective component data sheet in order to understand the
characteristic and performance of the individual component before carryout experiment.Always check the pneumatic compressor and the connection of circuit before test and run.
Refer to safety precaution section for further details to avoid hazards.
Component list
No Component Quantity
1 3/2 way valve push button actuation spring return 3
2 5/2 way valve air actuation spring return 1
3 5/2 way valve air actuation air return 2
4 Double acting cylinder 2
5 Air service unit 1
6 Compressor 1
Note: The pneumatic tubing is require in the system in order to connecting the components
assembly circuit, the length of the tubing uses is subject to the position of thecomponent.
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Exercise 4 solution
Following constructed circuit diagram show the function with two cylinder, 5/2 way
valve air actuation spring return, 5/2 way valve air actuation air return and start push button..
Circuit diagram 4
Double acting cylinder 1 Double acting cylinder 2
5/2 way valve
Air actuation
air return
5/2 way valve
Air actuation
spring return
3/2 way valve
push button actuation
spring return 1
3/2 way valve
push button
actuation spring
return 2
3/2 way valve
push button
actuation spring
return 3
Air service unit
Com ressor
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Exercise 5 Press push button 1 or 2 cylinder extend press push button 3 cylinder retract
Description
This exercise is to learn the function of or gate in the pneumatic system. The test circuit is
to show how the air pressure flow through the pneumatic component and learn thecharacteristic of the pneumatic component. The user require to observing the function andthe condition of circuit.
Precaution
The trainee shall read the respective component data sheet in order to understand thecharacteristic and performance of the individual component before carryout experiment.
Always check the pneumatic compressor and the connection of circuit before test and run.
Refer to safety precaution section for further details to avoid hazards.
Component list
No Component Quantity
1 3/2 way valve push button actuation spring return 3
2 5/2 way valve air actuation air return 1
3 Double acting cylinder 1
4 Air service unit 1
5 Compressor 1
6 Or gate 1
Note: The pneumatic tubing is require in the system in order to connecting the componentsassembly circuit, the length of the tubing uses is subject to the position of thecomponent.
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Exercise 5 solution
Following constructed circuit diagram show the function of OR gate
Circuit diagram 5
Double acting cylinder
5/2 way valve
Air actuation
air return
3/2 way valve
push button actuation
spring return 1
3/2 way valve
push button actuation
spring return 3
Or gate
Air service unit
Compressor
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Exercise 6 Press push button 1 or 2 cylinder extend, roller limit switch cylinder retract
Description
This exercise is to learn the function of roller limit switch in the pneumatic system. The
test circuit is to show how the air pressure flow through the pneumatic component andlearn the characteristic of the pneumatic component. The user require to observing thefunction and the condition of circuit.
Precaution
The trainee shall read the respective component data sheet in order to understand thecharacteristic and performance of the individual component before carryout experiment.
Always check the pneumatic compressor and the connection of circuit before test and run.
Refer to safety precaution section for further details to avoid hazards.
Component list
No Component Quantity
1 3/2 way valve push button actuation spring return 2
2 5/2 way valve air actuation air return 1
3 Double acting cylinder 1
4 Roller limit switch 1
5 Air service unit 1
6 Compressor 1
7 Or gate 1
Note: The pneumatic tubing is require in the system in order to connecting the components
assembly circuit, the length of the tubing uses is subject to the position of thecomponent.
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Exercise 6 solution
Following constructed circuit diagram show the function with roller limit switch
Circuit diagram 6
Double acting cylinder
5/2 way valve
Air actuation
air return
3/2 way valve
push button actuation
spring return 1
3/2 way valve
Roller limit switch
actuation spring return
Compressor
Air service unit
Or gate
Roller limit switch
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Exercise 7 Press push button1 cylinder 1 extend, roller limit switch 2 sense cylinder 2extend press start push button 2 cylinder 1 and 2 retract.
Description
This exercise is to learn the function cylinder and valve with variable task in the pneumatic system. The test circuit is to show how the air pressure flow through the pneumatic component and learn the characteristic of the pneumatic component. The user
require to observing the function and the condition of circuit.
Precaution
The trainee shall read the respective component data sheet in order to understand the
characteristic and performance of the individual component before carryout experiment.
Always check the pneumatic compressor and the connection of circuit before test and run.Refer to safety precaution section for further details to avoid hazards.
Component list
No Component Quantity
1 3/2 way valve push button actuation spring return 2
2 5/2 way valve air actuation air return 1
3 Double acting cylinder 2
4 Air service unit 1
5 Compressor 1
6 Roller limit switch 1
7 5/2 way valve air actuation spring return 1
Note: The pneumatic tubing is require in the system in order to connecting the componentsassembly circuit, the length of the tubing uses is subject to the position of thecomponent.
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Exercise 7 solution
Following constructed circuit diagram show the function with cylinder and valve with
different task.
Circuit diagram 7
Double acting cylinder 1 Double acting cylinder 2
3/2 way valve
push button actuation
spring return 1
Air service unit
5/2 way valve
Air actuation
air return
5/2 way valve
Air actuationspring return
Compressor
Roller limit
switch
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ENGINEERING MAKES DIFFERENT 24
Exercise 8 When cylinder touch roller limit switch 1 cylinder will extend, roller limitswitch 2 sense then cylinder will retract. This system called oscillation
system
Description
This exercise is to learn the function oscillation system in the pneumatic system. The testcircuit is to show how the air pressure flow through the pneumatic component and learn
the characteristic of the pneumatic component. The user require to observing the function
and the condition of circuit.
Precaution
The trainee shall read the respective component data sheet in order to understand the
characteristic and performance of the individual component before carryout experiment.Always check the pneumatic compressor and the connection of circuit before test and run.
Refer to safety precaution section for further details to avoid hazards.
Component list
No Component Quantity
1 5/2 way valve air actuation air return 1
2 Double acting cylinder 2
3 Air service unit 1
4 Compressor 1
5 Roller limit switch 2
Note: The pneumatic tubing is require in the system in order to connecting the componentsassembly circuit, the length of the tubing uses is subject to the position of the
component.
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Exercise 8 solution
Following constructed circuit diagram show the function of oscillation system without
start push button.
Circuit diagram 8
Double acting cylinder 1
3/2 way valve
Roller limit switch
actuation spring return 2
5/2 way valve
Air actuation
air return
3/2 way valve
Roller limit switch
actuation spring return 1
Air service unit
Compressor
Roller limit Switch
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Exercise 9 Press push button 1 cylinder will oscillation(continuous) until press push button 2
Description
This exercise is to learn the function oscillation system with control system in the pneumatic system. The test circuit is to show how the air pressure flow through the pneumatic component and learn the characteristic of the pneumatic component. The user
require to observing the function and the condition of circuit.
Precaution
The trainee shall read the respective component data sheet in order to understand the
characteristic and performance of the individual component before carryout experiment.
Always check the pneumatic compressor and the connection of circuit before test and run.Refer to safety precaution section for further details to avoid hazards.
Component list
No Component Quantity
1 5/2 way valve air actuation air return 2
2 Double acting cylinder 1
3 Air service unit 1
4 Compressor 1
5 Roller limit switch 2
6 3/2 way valve push button actuation spring return 2
Note: The pneumatic tubing is require in the system in order to connecting the componentsassembly circuit, the length of the tubing uses is subject to the position of thecomponent.
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Exercise 9 solution
Following constructed circuit diagram show the function of oscillation system with start
push button.
Circuit diagram 9
Double acting cylinder 1
5/2 way valve
Air actuation
air return
Roller limit Switch
5/2 way valve
Air actuation
air return
Air service unit
Compressor
3/2 way valve
Roller limitswitch actuation
spring return
3/2 way valve
Roller limitswitch actuation
spring return
3/2 way valve
Push button
actuation springreturn
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Exercise 10 A+ B+ A- B-
Description
This exercise is to understand the function of pneumatic system. The test circuit is to
show how the air pressure flow through the pneumatic component and learn thecharacteristic of the pneumatic component. The user require to observing the function andthe condition of circuit.
Precaution
The trainee shall read the respective component data sheet in order to understand thecharacteristic and performance of the individual component before carryout experiment.
Always check the pneumatic compressor and the connection of circuit before test and run.
Refer to safety precaution section for further details to avoid hazards.
Component list
No Component Quantity
1 5/2 way valve air actuation air return 3
2 Double acting cylinder 2
3 Air service unit 1
4 Compressor 1
5 Roller limit switch 4
6 3/2 way valve push button actuation spring return 2
Note: The pneumatic tubing is require in the system in order to connecting the componentsassembly circuit, the length of the tubing uses is subject to the position of thecomponent.
Sequence
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Exercise 10 solution
Following constructed circuit diagram show the function of A+ B+ A- B- system
Circuit diagram 10
Double acting cylinder 1
5/2 way valve
Air actuation
air return
Roller limit Switch
3/2 way valve
Roller limit
switch actuation
spring return
3/2 way valve
Push button
actuation spring
return
Roller limit SwitchDouble acting cylinder 2
5/2 way valve
Air actuation
air return
3/2 way valveRoller limit
switch actuation
spring return
Air service unit
Compressor
3/2 way valve
Roller limit
switch actuation
spring return