pneumatic technology

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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]




Contents

Section Description Page

A Safety Instruction 3-4

Introduction 5Pneumatic training kit 6Component symbol 7-8

B Exercise 9-29




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.




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.

mailto:[email protected]

mailto:[email protected]




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.




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




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




No Symbol Component

8 Air filter

9 Pressure regulator

10 Pressure gauge

11

Air service unit




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




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




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.




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 service unit

Compressor




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.


Component list



2 5/2 way valve air actuation air return 1



5 Compressor 1


component.




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.


3/2 way valve


spring return

3/2 way valve


spring return

Air service unit

Compressor

5/2 way valve

Air actuation

air return




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


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






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.




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


spring return 1

3/2 way valve

push button

actuation spring

return 2

Air service unit

Com ressor




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


Precaution


characteristic and performance of the individual component before carryout experiment.Always check the pneumatic compressor and the connection of circuit before test and run.


Component list







6 Compressor 1






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


5/2 way valve

Air actuation

air return

5/2 way valve

Air actuation

spring return

3/2 way valve


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




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




Component list






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.




Exercise 5 solution

Following constructed circuit diagram show the function of OR gate

Circuit diagram 5


5/2 way valve

Air actuation

air return

3/2 way valve


spring return 1

3/2 way valve


spring return 3

Or gate

Air service unit

Compressor




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




Component list





4 Roller limit switch 1


6 Compressor 1

7 Or gate 1






Exercise 6 solution

Following constructed circuit diagram show the function with roller limit switch

Circuit diagram 6


5/2 way valve

Air actuation

air return

3/2 way valve


spring return 1

3/2 way valve

Roller limit switch

actuation spring return

Compressor

Air service unit

Or gate

Roller limit switch




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


Precaution




Component list






5 Compressor 1







Exercise 7 solution

Following constructed circuit diagram show the function with cylinder and valve with

different task.

Circuit diagram 7


3/2 way valve


spring return 1

Air service unit

5/2 way valve

Air actuation

air return

5/2 way valve


Compressor

Roller limit

switch




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


characteristic and performance of the individual component before carryout experiment.Always check the pneumatic compressor and the connection of circuit before test and run.


Component list





4 Compressor 1



component.




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




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


Precaution




Component list





4 Compressor 1







Exercise 9 solution

Following constructed circuit diagram show the function of oscillation system with start

push button.

Circuit diagram 9


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




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




Component list





4 Compressor 1




Sequence



Exercise 10 solution

Following constructed circuit diagram show the function of A+ B+ A- B- system

Circuit diagram 10


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

pneumatic technology

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