Pneumatics

Cylinder Selection
Cylinder Selection
Determined by the force required to move the load and the speed required. Hydraulic cylinders are capable of greater forces; pneumatic cylinders are capable of greater speeds. Piston Force A small percentage of the applied force is used to overcome friction, with the remainder applied to the load.
F = PA - R
Piston Speed The speed v of a hydraulic cylinder is equal to the flow rate of liquid Q through the cylinder divided by the crosssectional area A of the cylinder.
Q v= A
Hydraulic Cylinder Example

Consider a hydraulic cylinder used to move a work piece in a manufacturing operation through a distance of 250 mm in 15 seconds. If a force of 5 kN is required to move the work piece, what is the required working pressure and hydraulic liquid flow rate if a cylinder with a piston diameter of 125 mm is available?
0.250 0.125 = = 15 2
2
= 0.0002 3
Pressure vs. Force for Pneumatic Cylinders
Pressure vs. Force for Pneumatic Cylinders
Cylinder Buckling Strength

When an excess thrust is applied to a cylinder, the buckling strength must be taken into consideration. Conditions leading to excess thrust include: 1. Compression stress. 2. The stressed part (i.e. piston rod) is long and slender. The buckling strength depends greatly on the mounting method. Eulers column formula (for round sections): Pcr n 2 EA (l Rg ) 2
Pcr n E A = critical (maximum) load = end condition coefficient = modulus of elastisity = cross-sectional area
Rigidly fixed on one side and loose at the opposite end. (n = )
Pivoting on both ends. (n = 1)
Rigidly fixed on one side and pivoting at the other. (n = 2)
Rigidly fixed at both ends. (n = 4)
l
Rg
= length of column
= least radius of gyration
Radius of Gyration
Rg I A
where I is second moment of area of piston rod
where l is the effective (revealed or unsupported) piston rod length
l Rg slenderness ratio
Cylinder Buckling Strength

For most cylinders, maximum allowable loads (Pcr) are determined by the manufacturer:
Pressure and Flow Control
Pressure Control Valves

There are three main types of pressure control valves: 1. Pressure regulating valves
Used to control the operating pressure in a circuit and maintain it at a constant value.
2. Pressure limiting valves

Used as safety devices to maintain the pressure in a circuit below some safe value. If pressure rises above the set safe value, the valve opens and vents to the atmosphere or returns to the sump.
3. Pressure sequence valves

Used to sense the pressure of an external line and give a signal when it reaches a preset value.
Pressure Limiting Valve

Example to right has one orifice that is normally closed. When the inlet pressure (force on ball) exceeds the force applied by the spring, the valve opens and vents to the atmosphere, or back to the sump. Spring force (set limit value) is adjustable.
Pressure Sequence Valve

Adaptation of pressure limiting valve. Allows flow to occur when the inlet pressure exceeds a set value. Applications include starting an automatic machine operation once the clamping pressure applied to the workpiece has reached a certain level.
Flow Rating
Flow rating is a measure of a components ability to pass air at an acceptable pressure drop.
Usually pressure drop should not exceed 10% of supply pressure.
One method of expressing the flow rating is by assigning a coefficient called the CV factor.
CV flow in cfm 35 10 flow in litres/min 1000
-6
For a cylinder:
CV cylinder bore area stroke compression pressure drop single stroke time 29
The higher the CV factor, the greater the flow rating of the component. Components can also be rated in standard cubic feet per minute (scfm) where flow is measured at 60F (16C) and 15 psi (1 bar). When defining the flow rating of a component, the temperature and pressure must be specified.
Pneumatic EconomicsWork from Air

How much work can be performed by 1 m3 of air? Consider a cylinder 35 mm in diameter raising packages weighing 20 kg. A second cylinder of the same diameter pushes the packages onto a conveyor belt. The stroke of the first cylinder is 400 mm; the stroke of the second is 200 mm.
The compressive force at 6 bar (600 kPa or 90 psi) is 520 N. For both cylinders, 0.001 m3 of air is used per double stroke (in/out).
Thus, with 1 m3 of air, 1000 packages can be lifted and pushed onto the conveyor belt.
Effects of Leakage
The cost of compressed air can rise considerably unless careful watch is kept for leaks in the piping. Even small leaks can lead to increased costs. Graph to right demonstrates the relationship between escape rate and area of aperture at various pressures.
Additional Reference Material

The following slides are were not visited in class lectures. They are provided here for your future reference.
Process Control Valves

Used to control the rate of fluid flow. May be used to control the rate of flow of a liquid into a tank. The basic principle involves an actuator that is used to move a plug into the flow pipe, thereby altering the pipe cross-section. Process control valves consist of three main components: 1. Actuator. 2. Valve body. 3. Plug.
Diaphragm Actuator
Common form of pneumatic actuator used with process control valves. Consists of a diaphragm with an input pressure signal from the controller on one side and atmospheric pressure on the other. Pressure difference is gauge pressure. Diaphragm is made of a rubber centre sandwiched between two steel discs.
Diaphragm Actuator
Movement of the diaphragm is communicated to the final control element by an attached shaft. For a linear-response restoring spring (i.e., F = kx, where k is constant), the displacement of the shaft is proportional to the gauge pressure (i.e., kx = PA).
Valve Bodies
There are many forms of valve bodies. Primary forms are single seated and double seated. Single seated refers to a valve having a single path for the fluid through the valve. Only one plug is required to control the flow. Can be closed more tightly than a double-seated valve. Force on plug due to flow is much higher, requiring the diaphragm to exert considerably higher forces on the stem.
Valve Bodies
Double seated refers to a valve where the fluid entering the valve body splits into two streams. Each stream passes an orifice controlled by a plug. Requires two plugs. Lower stem forces are required to close the valve than a single-seated valve.
Plugs
The shape of the plug determines the relationship between the stem movement and the effect on the flow rate.
Current to Pressure Converter

Conversion of electrical current into a gauge pressure for control purposes (specifying diaphragm displacement of a process control valve) may be accomplished using an apparatus such as illustrated below:
Current through coils causes lever to be attracted to magnet. Corresponding movement of flapper over nozzle is produced. Flapper position controls rate of air escape and hence air pressure in the system. Springs on the flapper are used to adjust the sensitivity of the converter. Currents of 4 to 20 mA produce gauge pressures of 20 to 100 kPa.
Hydraulics
Actuator Power to Weight Ratios

104
103 Power/Weight ratio [W/kg] Shape memory metals 102 Pneumatic actuators
Hydraulic actuators
10 DC motors
1 10-2 10-1 1 Weight [kg] 10 102
Hydraulic Systems
Advantages
Very powerful, suitable for tasks requiring large forces. Capable of higher maximum acceleration than DC motors. Strokes from a few millimetres to metres in length. Speeds and forces are infinitely adjustable. Small time constants result in smooth motion.
Disadvantages
Use of fluids can be messy and noisy when improperly applied. Generally not suitable for processes requiring a clean operating environment. Hydraulic oil can be volatile. Installation of hydraulic components is relatively expensive. Components (and fluid) are heavy.
Time constant
The time it takes to observe a significant change in a given process.
Hydrostatic Force Multiplier

F = P1A1 = P2 A2
Hydrostatic Force Multiplier

A2 F2 F1 A1
F2 P2 A2
P 1
F1 A1
F1d1 F2 d 2 Work in Work out F2 A2 d1 d 2 d 2 F1 A1
d1 F2 A2 d 2 F1 A1
Hydraulic Power Supply

Pressurized oil is provided by a pump driven by an electric motor. Accumulator is just a container in which the oil is held under pressure against an external force.
Accumulator

Pneumatics

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Cylinder Selection

Hydraulic Cylinder Example

Pressure vs. Force for Pneumatic Cylinders

Pressure vs. Force for Pneumatic Cylinders

Cylinder Buckling Strength

Rigidly fixed on one side and loose at the opposite end. (n = )

Pivoting on both ends. (n = 1)

Rigidly fixed on one side and pivoting at the other. (n = 2)

Rigidly fixed at both ends. (n = 4)

where I is second moment of area of piston rod

where l is the effective (revealed or unsupported) piston rod length

Cylinder Buckling Strength

Pressure and Flow Control

Pressure Control Valves

2. Pressure limiting valves

3. Pressure sequence valves

Pressure Limiting Valve

Pressure Sequence Valve

Pneumatic EconomicsWork from Air

Additional Reference Material

Process Control Valves

Current to Pressure Converter

Actuator Power to Weight Ratios

1 10-2 10-1 1 Weight [kg] 10 102

Hydrostatic Force Multiplier

Hydrostatic Force Multiplier

F1d1 F2 d 2 Work in Work out F2 A2 d1 d 2 d 2 F1 A1

Hydraulic Power Supply

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