7/30/2016

NPTELPhaseII::Automationandcontrols

Module3:Electropneumatics
Relaycontrolsystem

Applicationsofrelaycontrolsystemsinelectropneumatics:

Theentiresignalprocessingneedsofanelectropneumaticcontrolsystemcanbeimplementedwithrelays.
Nowadaysprogrammablelogiccontrollers(PLCs)arecommonlyusedforsignalprocessinginsteadofrelay
controlsystems.
Relaysarestillusedinmoderncontrolsystemshowever,forexampleinanEMERGENCYSTOPswitchingdevice.
Theprincipaladvantagesofrelaycontrolsystemsaretheclarityoftheirdesignandtheeaseofunderstanding
theirmodeofoperation.

DirectandIndirectControl:

DirectControl:
ThepistonrodofasingleactingcylinderistobeextendedwhenpushbuttonS1ispressedandretractedwhen
thepushbuttonisreleased.
IndirectControl:
Ifthepushbuttonispressedinanindirectcontrolsystem,currentflowsthroughtherelaycoil.ContactK1of
therelaycloses,andthedirectionalcontrolvalveswitches.Thepistonrodadvances.

DirectControlofSingleActingCylinder:

TheelectricalcircuitdiagramfordirectcontrolofasingleactingcylinderisshowninFigure.

IndirectControlofSingleActingCylinder:

TheelectricalcircuitdiagramforindirectcontrolofasingleactingcylinderisshowninFigure.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

1/35

7/30/2016

NPTELPhaseII::Automationandcontrols

DirectControlofDoubleActingCylinder:

TheelectricalcircuitdiagramfordirectcontrolofaDoubleactingcylinderisshowninFigure.

IndirectControlofDoubleActingCylinder:

TheelectricalcircuitdiagramforindirectcontrolofaDoubleactingcylinderisshowninFigure.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

2/35

7/30/2016

NPTELPhaseII::Automationandcontrols

LogicOperations:

Combinesignalsfromseveralcontrolelementsthroughlogicoperations.
ParallelConnection(ORCircuit):
Theaimistobeabletotriggerextendofthepistonrodofacylinderwithtwodifferentinputelements,
pushbuttonsS1andS2.
ThecontactsofthetwopushbuttonsS1andS2arearrangedinparallelinthecircuitdiagram.

Parallel(ORCircuit):

LogicOperations:

SeriesConnection(ANDCircuit):
http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

3/35

7/30/2016

NPTELPhaseII::Automationandcontrols

Inthiscasethepistonrodofacylinderistobeadvancedonlyifbothpushbuttons,S1andS2,arepressed.
Thecontactsofthetwopushbuttonsarearrangedinseriesinthecircuitdiagram

Series(ANDCircuit):

RepresentationofLogicinTabularForm:

TheORandANDoperationsareshowninsummarizedforminTables.
Thefollowingvaluesareassignedtothesignalsinthethreerighthandcolumns:
0:Pushbuttonnotpressedorpistonroddoesnotadvance.
1:Pushbuttonpressedorpistonrodadvances.
http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

4/35

7/30/2016

NPTELPhaseII::Automationandcontrols

SignalStorage:

Inthecircuitsthatwehavelookedatsofar,thepistonrodonlyadvancesaslongastheinputpushbuttonis
actuated.Ifthepushbuttonisreleasedduringtheadvancingmovement,thepistonrodisretractedwithout
havingreachedtheforwardendposition.
Inpracticeitisusuallynecessaryforthepistonrodtobefullyadvancedevenifthepushbuttonispressedonly
briefly.
Toachievethis,thedirectionalcontrolvalvemustremainintheactuatedpositionwhenthepushbuttonis
releasedinotherwords,actuationofthepushbuttonmustbestored.
Adoublesolenoidvalvemaintainsitsswitchingpositionevenwhentheassociatedsolenoidcoilisnolonger
energized.Itisusedasastorageelement.
Thepistonrodofacylinderistobecontrolledbybriefactuationoftwopushbuttons(S1:advance,S2:retract).

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

5/35

7/30/2016

NPTELPhaseII::Automationandcontrols

AutomaticReturnStroke:

TheaimisforthepistonrodofadoubleactingcylindertobeadvancedwhenpushbuttonS1isactuated.
Whentheforwardendpositionisreached,thepistonrodistoreturnautomatically.
UsingDoubleSolenoidandLimitSwitch.
TheprerequisiteforthereturnmovementisthatpushbuttonS1mustfirsthavebeenreleased.

OscillatingMovement:

ThepistonrodofacylinderistoadvanceandretractautomaticallyassoonascontrolswitchS1isactuated.
http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

6/35

7/30/2016

NPTELPhaseII::Automationandcontrols

Whenthecontrolswitchisreset,thepistonrodistooccupytheretractedendposition.

RelayCircuitwithLatching:

Whenthe"ON"pushbuttonisactuatedinthecircuit,therelaycoilisenergized.Therelayisenergised,and
contactK1closes.
Afterthe"ON"pushbuttonisreleased,currentcontinuestoflowviacontactK1throughthecoil,andtherelay
remainsintheactuatedposition.
The"ON"signalisstored.Thisisthereforearelaycircuitwithlatchingfunction.

DominantON:
Whenthe"OFF"pushbuttonispressedtheflowofcurrentisinterruptedandtherelaybecomesdeenergised.
Ifthe"ON"and"OFF"pushbuttonsarebothpressedatthesametime,therelaycoilisenergized.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

7/35

7/30/2016

NPTELPhaseII::Automationandcontrols

ThiscircuitisreferredtoasadominantONlatchingcircuit.

DominantOFF:
Whenthe"OFF"pushbuttonispressedtheflowofcurrentisinterruptedandtherelaybecomesdeenergised.
Ifthe"ON"and"OFF"pushbuttonsarebothpressedatthesametime,therelaycoilisenergized.
ThiscircuitisreferredtoasadominantONlatchingcircuit.

CylinderControlwithLatchingCircuit:

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

8/35

7/30/2016

NPTELPhaseII::Automationandcontrols

ComparisonOfSignalStorageCircuit:

Signalstoragecanbeeffectedbymeansof:
Adoublesolenoidvalveinthepowersection.
Alternativelyinthesignalcontrolsectionbymeansofarelaywithlatchingfunction.
Thevariouscircuitsbehavedifferentlyinresponsetothesimultaneouspresenceofasettingandresetting
signal,andintheeventoffailureoftheelectricalpowersupplyorawirebreak

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

9/35

7/30/2016

NPTELPhaseII::Automationandcontrols

TimeDelay:

Inmanyapplicationsitisnecessaryforthepistonrodofapneumaticcylindertoremainatacertainpositionfor
asetlengthoftime.
Thisisthecaseforthedriveofapressingdevice,forexample,whichpressestwoworkpiecestogetheruntilthe
adhesivehasset.
Timerelayswithdelayedswitchonorswitchoffareusedfortaskssuchasthese.

ControlofCylinderwithTiming:

WhenpushbuttonS1ispressedmomentarily,thepistonrodofacylinderistoadvance,subsequentlyremainat
theforwardendpositionfortensecondsandthenautomaticallyreturn.

Sequencecontrolwithsignalstoragebydoublesolenoidvalves:

ThepositionalsketchofafeedingdeviceisshowninFigure.
Theendpositionsofthetwocylinderdrives1Aand2Aaredetectedbythepositiveswitchinginductive
proximityswitches1B1and2B2.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

10/35

7/30/2016

NPTELPhaseII::Automationandcontrols

FeedingDevice:

Theprogramcontrolledsequenceistriggeredwhentheoperatorpressesthe"START"pushbutton.Thesequence
comprisesthefollowingsteps:
Step1:Thepistonrodofcylinder1Aadvances.Theworkpieceispushedoutofthemagazine.
Step2:Thepistonrodofcylinder2Aadvances.Theworkpieceisfedtothemachiningstation.
Step3:Thepistonrodofcylinder1Aretracts.
Step4:Thepistonrodofcylinder2Aretracts.

DisplacementStepDiagram:

Pneumaticcircuit:

Thecontrolsystemisimplementedusingdoubleactingcylindersand5/2waydoublesolenoidvalves.
http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

11/35

7/30/2016

NPTELPhaseII::Automationandcontrols

DesignofRelayCircuitDiagram:

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

12/35

7/30/2016

NPTELPhaseII::Automationandcontrols

Inarelaycircuitthesignalsarecombinedwitheachotherbythecontactsofcontrolswitches,pushbuttonsand
relays.
Theelectronicproximityswitchesusedheredonothavecontactsinsteadtheygenerateanoutputsignalby
meansofanelectroniccircuit.
Eachsensoroutputsignalthereforeactsonthecoilofarelay,whichinturnswitchesthenecessarycontactor
contacts.

SensorEvaluation:

FirstSequenceStep:

Thefollowingpreconditionsmustbesatisfiedbeforethesequenceisstarted:
1.Pistonrodofcylinder1Ainretractedendposition(proximityswitch1B1andrelayK1actuated).
2.Pistonrodofcylinder2Ainretractedendposition(proximityswitch2B1andrelayK3actuated).
3.STARTpushbutton(S5)actuated.
Ifalloftheseconditionsaremet,relaycoilK6isenergised.Solenoidcoil1Y1isactuated,andthepistonrodof
cylinder1Aadvances.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

13/35

7/30/2016

NPTELPhaseII::Automationandcontrols

SecondSequenceStep:

Whenthepistonrodofcylinder1Areachestheforwardendposition,sensor1B2responds.Thesecondstepof
thesequenceisactivated.Solenoidcoil2Y1isactuated,andthepistonrodofdrive2Aadvances.

ThirdSequenceStep:

Whenthepistonrodofcylinder2Areachestheforwardendposition,sensor2B2responds.Thethirdstepofthe
sequenceisactivated.Solenoidcoil1Y2isactuated,andthepistonrodofdrive1Aretracts.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

14/35

7/30/2016

NPTELPhaseII::Automationandcontrols

FourthSequenceStep:

Whenthepistonrodofcylinder1Areachestheretractedendposition,sensor1B1responds.Thefourthstepof
thesequenceisactivated.Solenoidcoil2Y2isactuated,andthepistonrodofdrive2Aretracts.

CircuitforControlElements:

ImportantcontrolelementssuchasamainswitchandEMERGENCYSTOPswitcharemissing.
Controlswitches(latchingtypeswitches)mustbeusedforswitchingonelectricalpowerandforthe
EMERGENCYSTOPfunction.
Allothercontrolelementsmaytaketheformofeitherpushbuttons(momentarycontactswitches)orcontrol
switches.
IntheFeedingDeviceCircuit,thecontrolelementsfor:
"Manual"
"Reset"
"Automatic"
"ContinuouscycleON"
http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

15/35

7/30/2016

NPTELPhaseII::Automationandcontrols

"ContinuouscycleOFF"
"SinglecycleStart"areimplementedaspushbuttons.

FeedingDevicewithControlElements:

MainSwitch:
Whenthemainswitchisclosed,relayK1isenergised.Voltageissuppliedtothesignalcontrolsectionandthe
entiresystemviacontactK1.
EmergencyStop:
http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

16/35

7/30/2016

NPTELPhaseII::Automationandcontrols

IftheEMERGENCYSTOPswitchisactuated,relayK2isdeenergizedandtheassociatedcontactsswitchtothe
normalposition.
TheEMERGENCYSTOPlineisconnectedtothesupplyvoltageviathenormallyclosedcontactofK2.Warning
lampscanbeactuatedviathisline,forexample.
The"EMERGENCYSTOPreleased"lineisdeenergized,causingthevoltagesupplytothesignalcontrolsection
tobeinterrupted.AslongasEMERGENCYSTOPapplies,allcontrolelementsexceptthemainswitcharerendered
inoperative.
ManualOperation:
Whenthe"Manual"pushbuttonisactuated,relayK4picksupandlatches.Thelinemarked"Manual"inthe
circuitdiagramisconnectedtothesupplyvoltage.
IfrelayK3islatched,thelatchingisreleased.Thelinemarked"Automatic"isdisconnectedfromthesupply
voltage.
AutomaticOperation:
Whenthe"Automatic"pushbuttonisactuated,relayK3isenergisedandlatches.Thelinemarked"Automatic"
inthecircuitdiagramisconnectedtothesupplyvoltage.
IfrelayK4islatched,thelatchingisreleased,andthelinemarked"Manual"isdisconnectedfromthesupply
voltage.
ContinuouscycleON
ContinuouscycleOFF
SinglecycleStart:
Thesefunctionsareonlypossibleinautomaticmode.Electricalpoweristhereforesuppliedtotheassociated
contactsandrelaysviathelinemarked"Automatic".

AutomaticOperation:

If"Automatic"modeisselected(relayK3latched)and"ContinuouscycleON"isactive(relayK5latched),the
controlsystemrunsincontinuousoperation.
Actuatingthe"ContinuouscycleOFF"pushbuttonreleasesthelatchingofrelayK5.Theprogramcontrolled
sequencestopsassoonasthelaststepinthesequenceiscompleted.
Whenthe"SinglecycleStart"pushbuttonisactuated,thesequence(movementcycle)isexecutedonceonly.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

17/35

7/30/2016

NPTELPhaseII::Automationandcontrols

DesignofaLiftingDevice:

Aliftingdevicetransfersworkpiecesfromonerollerconveyortoanotheratadifferentheight.
ApositionalsketchoftheliftingdeviceisshowninFigure.Therearethreepneumaticdrives:
1.Drive1Aliftstheworkpieces.
2.Drive2Apushestheworkpiecesontotheupperrollerconveyor.
3.Drive3Aisusedasastopper,forreleasingandinterruptingthesupplyofworkpieces.

SafetyRequirement:
http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

18/35

7/30/2016

NPTELPhaseII::Automationandcontrols

Topreventthepossibilityofsecondarydamage,intheeventofanelectricalpowerfailurethepistonrodsof
cylinders1Aand2Aaretobebrakedimmediatelyandremainatastandstill.
Thepistonrodofthestoppercylinder3Aismeanttoextendinthesecircumstances.

MovementCycle:

OperatorControl:

Thecontrolsystemoftheliftingdevicemustenablethedevicetoberuninacontinuouscycle(continuous
operation).
Asinglecycleoperatingmodeisalsonecessaryinwhichthesequenceisprocessedpreciselyonce.

OperatorControlPanel:

OperatingFunctions:

Thefollowingoperatingfunctionsarespecifiedforliftingdevice:
"EMERGENCYSTOP":Whenthisisactuated,notonlytheelectricalpowersupply,alsothepneumaticpower
supplymustbeshutdown.
http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

19/35

7/30/2016

NPTELPhaseII::Automationandcontrols

"Reset":Thisreturnsthesystemtotheinitialposition,i.e.thepistonrodsofcylinders1Aand2Aretract,the
pistonrodofcylinder3Aextends.
"ContinuouscycleOFF":Thisstopsthecontinuouscycleprocess.Ifthereisalreadyaworkpieceinthe
device,itistransferredtotheupperrollerconveyor.Thepistonrodsofcylinders1Aand2Aretract.Thedeviceis
subsequentlyinitsinitialposition.

ElectricalCircuit:

Designofarelaycontrolsystemwithclearlydefinedrequirementsastooperatorcontrol,operational
performanceandbehaviorintheeventofafault.
Therelaycontrolsystemisdesignedinthefollowingorder:
1.Powersupply.
2.Sensorevaluation.
3.Operatorcontrol.
4.Programcontrolledsequence.
5.Wiringofsolenoids.

FlowChart:

MainSwitch&EMERGENCYStop:

SimplifiedEmergencyControl.
EMERGENCYSTOPsignalisrequiredininvertedformonly.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

20/35

7/30/2016

NPTELPhaseII::Automationandcontrols

PneumaticCircuit:

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

21/35

7/30/2016

NPTELPhaseII::Automationandcontrols

SensorEvaluation:

ElectricalpowerissuppliedtothesensorsaslongastheEMERGENCYSTOPdeviceisnotactuated.RelaysK6to
K11areassignedtosensors1B1to3B1andB5

ManualandResetControl:

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

22/35

7/30/2016

NPTELPhaseII::Automationandcontrols

If"Manual"modeisselected(relayK4latched)andthe"Reset"pushbutton(S5)ispressed,relayK12isthen
latched.Theresetprocessisendedwhenthepistonrodsofthecylindersassumethefollowingpositions:
Cylinder1A:retractedendposition(sensor1B1responds,relayK6actuated).
Cylinder2A:retractedendposition(sensor2B1responds,relayK8actuated).
Cylinder3A:forwardendposition(sensor3B1responds,relayK11actuated).
Whenallthreeoftheseconditionsaremet,thelatchingofrelayK12isreleasedvianormallyclosedcontacts
K6,K8andK11.

AutomaticCycle:

Automatic:
ContinuouscycleON
ContinuouscycleOFF

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

23/35

7/30/2016

NPTELPhaseII::Automationandcontrols

ResetSequencerwithLatchingRelays:

SteppedSequenceimplementation:
Themovementprocessismadeupoffoursteps.RelaysK13(step1)toK16(step4)areassignedtothesefour
steps.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

24/35

7/30/2016

NPTELPhaseII::Automationandcontrols

SchematicDesignofStepSequence:

InterlockingofSteps:

Iftheprecedingstepisset(inthiscase:step1,normallyopencontactofrelayK13closed)andtheother
settingconditionsforstep2aresatisfied:
RelayK14switchestothelatchedposition.
ThelatchingofrelayK13isreleasedviathenormallyclosedcontactofrelayK14.
Thesecondstepinthesequenceisnowset,andthefirststepdeactivated

StepEnablingConditions:

Noneofthestepcanbesetunlesstherelayintheprecedingstepactuated.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

25/35

7/30/2016

NPTELPhaseII::Automationandcontrols

RelayCircuitStep1:

Toallowthefirstmovementsteptobeactivated,thefollowingconditionsmustbesatisfied:
>Pistonrodofcylinder1Ainretractedendposition(relayK6actuated).
>Pistonrodofcylinder2Ainretractedendposition(relayK8actuated).
>Pistonrodofcylinder3Ainforwardendposition(relayK11actuated).
>Step4active(relayK16actuated).
>Eithercontinuouscycleactive(relayK5latched)or"SinglecycleStart"(pushbuttonS7)actuated.
Ifalloftheseconditionsaresatisfied,relayK13islatchedandthefirststepisactive.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

26/35

7/30/2016

NPTELPhaseII::Automationandcontrols

FirsttoSecondStep:

IfopticalsensorB5respondswhilethefirststepisactive,thesettingconditionforthesecondstepissatisfied.
ThestepisactivatedbyactuationofrelayK14.RelayK14islatched,andthelatchingofrelayK13isreleasedby
thenormallyclosedcontactK14.

ThirdtoFourthStep:

Ifproximityswitch1B2respondswhilethesecondstepisactive,relayK15islatched.
ThelatchingofrelayK14isreleased.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

27/35

7/30/2016

NPTELPhaseII::Automationandcontrols

Ifproximityswitch2B2respondswhilethethirdstepisactive,relayK16islatched.
ThelatchingofrelayK15isreleased.

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

28/35

7/30/2016

NPTELPhaseII::Automationandcontrols

StartCondition:

Toenablethesequencetobestarted,thefourthstepofthesequence(relayK16)mustbeactivated.
Whenthesystemisswitchedtoautomaticmode,therefore,relaycoilK16isactuatedviathe"Automatic"line
andnormallyclosedcontactK17.
RelayK16islatched.CurrentflowsthroughthecoilofrelayK17viaanormallyopencontactofK16,andrelay
K17isalsolatched.
NomorecurrentflowsthroughthenormallyclosedcontactofK17.

RelayCircuitDiagram:

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

29/35

7/30/2016

NPTELPhaseII::Automationandcontrols

MainCircuit:

Thesolenoidcoilsofthedirectionalcontrolvalvesareactuatedwiththemaincircuits.
Thereare6coilsaltogether.Toallowpowertobesuppliedtothecoils,themainswitchmustbeinposition1
andtheEMERGENCYSTOPdevicemustnothavebeenactuated.
ThecompressedairisconnectedviarelayK18inordertopreventthepneumaticdrivesfrommovingbeforethe
relayshaveassumedadefinedposition.
Conditionsforactuationofthesolenoidcoils

PneumaticCircuit:
http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

30/35

7/30/2016

NPTELPhaseII::Automationandcontrols

SolenoidWiring:

ListofRelays:

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

31/35

7/30/2016

NPTELPhaseII::Automationandcontrols

ListofControlElements:

ControlElements:

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

32/35

7/30/2016

NPTELPhaseII::Automationandcontrols

SensorEvaluation:

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

33/35

7/30/2016

NPTELPhaseII::Automationandcontrols

SequenceStepSwitching:

SolenoidCircuit:

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

34/35

7/30/2016

NPTELPhaseII::Automationandcontrols

http://www.nptel.ac.in/courses/112102011/electropenumatics/relay%20control%20system.html

35/35