Pneumatics Practical Guide

pneumatics
pneumatics
Practical Guide
ADC-005-Pneu
from
pneumatics
Getting Fitted
Pneumatic Fittings
Fittings for connection to tubing and hose come in a variety of configurations including barb fittings, compression fittings, plastic/brass
Chapter
7
push-to-connect fittings, all metal push-to-connect fittings such as plated brass or stainless steel, brass threaded fittings, and quick-disconnect
air couplings which are mostly used with hose.
Barb fittings are a simple way to connect flexible tubing or hose. The tubing is simply pushed over a barb that is slightly larger than the
inside diameter of the tubing. A hose clamp is often added to secure the tubing more tightly. While easy to use, barb fittings have a higher
risk of leaking or of the tubing popping off.
Compression fittings use a small barrel-shaped piece called a ferrule that slips over the outside diameter of the tube and is then
compressed between a nut and the other half of the fitting. While creating a very secure connection, removing the tubing later can
be difficult and often the tubing is deformed to the point that a new tube must be used to reconnect the fitting.
Jump to
With push-to-connect fittings, flexible tubing is easily connected by inserting the tubing end into the fitting. To release the tubing, the circular Chapter
Chapter 1
release ring is pressed and the tubing is pulled out. This has become one of the most popular fittings for machinery and automation assemblies. Why Use
Pneumatics?
Plastic/brass push-to-connect fittings typically use strong thermoplastic with stainless steel tube- gripping claws, and threaded components Chapter 2
made of nickel-plated brass. These fittings provide an excellent solution for most applications. In harsher environments, more expensive Pneumatic Circuit
Symbols Explained
all-metal push-to-connect stainless steel fittings are commonly used, and these fittings are also preferred in high temperature and wash-down
applications. Chapter 3
Understanding
Pneumatic Air
Brass threaded fittings are a good choice for miscellaneous connections to many pneumatic devices, but typically don’t connect to tubing or Preparation
Chapter 4
hoses. Quick-disconnect air couplings are great for changing tool or hose connections and come in several sizes and materials. Pneumatic Actuator
(Air Cylinder) Basics
Thread Standards Chapter 5

Valves for
Pipe thread and tubing OD are two completely different things. A 1/4” tube fitting doesn’t necessarily have a 1/4” threaded connection at the Pneumatic
Cylinders
opposite end, so specify carefully. There are also several standard pipe threads including: Chapter 6
Pneumatic
• NPT (National Pipe Taper) Tubing &
Hose
• BSPT (British Std Pipe Taper) Chapter 7
• BSPP (British Std Pipe Parallel) Pneumatic
Fittings
NPT is the most commonly used in the U.S. and has a tapered thread. Thread standards should never be mixed on a machine, as a BSPT male Chapter 8
Are Pneumatic
thread fitting won’t mate correctly with a NPT female thread fitting. Although they will screw together, the thread angle is different and thus Components
Compatibl9
won’t create a proper seal.
Chapter 9
Electro Pneumatic
Systems in Acti
Chapter 10
Pneumatic
System Design
Considerations
Chapter 11
Energy Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
vs. Electromechanical
Chapter 13
Application
Stories
Chapter 7
30
pneumatics
Pneumatic Fittings
NPT can be referenced multiple ways. MNPT, MPT and NPT(M) all mean the fitting has male threads and uses the NPT standard. Female thread
Chapter
is labeled in a similar fashion, but with an F instead of an M. NPT fittings require thread sealant when installed, such as Teflon tape, but only
7
if not provided with sealant from the factory.
BSPT is sometimes called R-thread and is most commonly used in Europe, but is also sometimes used in the U.S. and Canada. BSPT fittings
require thread sealant when installed, such as Teflon tape, but only if not provided with sealant from the factory.
BSPP, also called G-thread, is less common, and a straight thread, but sometimes needed to connect certain standardized components. BSPP
threads don’t require thread sealant since they have an O-ring for sealing.
Tapered Thread Straight Thread

(NPT or BSPT) (BSPP)
Seal is accomplished Jump to
via metal-to-metal Chapter
wedging Chapter 1
Why Use
Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Seal is accomplished Chapter 3

via use of 0-ring, seal, Understanding
Pneumatic Air
or bonded washer Preparation
Chapter 4
Pneumatic Actuator
Figure 7A: Comparison of tapered and straight pipe threads
Chapter 5
Valves for
Special Purpose Fittings Pneumatic
Cylinders
Getting tubing connected between valves and cylinders often requires more than just a simple connector or elbow. Several special purpose Chapter 6
Pneumatic
push-to-connect fittings are available to improve integration and operation of pneumatic systems. Tubing &
Hose
Chapter 7
Flow Control Valves Pneumatic
Fittings
Flow control valves are often used on cylinders to control their speed. Flow control valves provide an adjustable restriction on the flow of air in
a single direction, while allowing free flow in the other direction. Two styles are available, inline and threaded types: Chapter 8
Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
Compatibl9
Chapter 9
Pneumatic
Electro Pneumatic
System Design
Systems in Action
Considerations
Chapter 10
Energy Efficient
Pneumatic
Pneumatic
System Systems
Design
Considerations
Chapter 11
Pneumatic
Energy Actuator
Efficient
Figure 7B: Inline style flow control Figure 7C: Threaded style flow control Pneumatic Systems
As their name suggests, inline flow controls are installed in the tubing lines, while the threaded versions are attached directly at the cylinder Chapter 12
Pneumatic Actuator
port. Meter-in flow controls meter the air going into a port, while meter-out valves restrict the flow of air as it leaves the port. To control the vs. Electromechanical
speed of a double-acting cylinder it is usually best practice to mount a threaded style meter-out flow control at the cylinder port. Metering the Chapter 13
air as it leaves the cylinder usually provided the smoothest cylinder action. Use a meter-out flow control on the extend port to control the speed Application
Stories
of retraction and use a meter-out flow control on the retract port to control the extension speed. With single-action (single port) spring-return
cylinders, a meter-in flow control valve may be required to control the extension speed.
Chapter 7
31
pneumatics
Pneumatic Fittings
Quick-Exhaust Valves
Chapter
Quick exhaust valves speed cylinder action by allowing exhaust air from either port to escape directly to the atmosphere without having to flow
7
back through the control valve. They have no effect on the air flowing into the cylinder port.
Figure 7D:Quick-exhaust valve

Jump to
Mini Shut-off (Hand) Valves Chapter
Chapter 1
These handy shut-off valves mount inline where ever you need on/off control of air. Choose a 2-way model for simple on/off control, or a Why Use
Pneumatics?
three-way design to vent downstream pressure when the valve is in the off position. A lock-out model is even available to prevent enabling
of a pneumatic circuit for maintenance or other purposes. Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Figure 7E: Shut-off valve Figure 7CF Locking shut-off valvel Valves for
Pneumatic
Cylinders
Pressure Regulators / Guages / Indicators Chapter 6
Pneumatic
Tubing &
Miniature push-to-connect pressure regulators, gauges, and indicators are small, lightweight, cost-effective, and easily added to existing Hose
circuits. Adjust pressure from 15 to 120 psi, monitor pressure from 0 to 170 psi, and even indicate active circuits (>29 psi) all in a minimum Chapter 7
Pneumatic
amount of space, anywhere on a machine (perfect for secondary branches). Fittings
Chapter 8
Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
Compatibl9
Chapter 9
Pneumatic
Electro Pneumatic
System Design
Systems in Action
Considerations
Chapter 10
Energy Efficient
Pneumatic
Pneumatic
System Systems
Design
Considerations
Chapter 11
Pneumatic
Energy Actuator
Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
Figure 7G: Special purpose push-to-connect pneumatic fittings vs. Electromechanical
Chapter 13
Application
Stories
Chapter 7
32
pneumatics
Pneumatic Fittings
Check Valves and Stop Valves

Chapter
Check valves allow air flow in one direction and block air flow in the reverse direction. Pilot-operated check valves work as a normal check valve
7
until pressure is applied to the pilot port allowing reverse flow. Stop valves block upstream air pressure when the downstream pneumatic tube
is removed from the fitting. Models are available with push-to-connect and/or threaded fittings.
Figure 7H:Check valve Figure 7I:Pilot operated check valve Figure 7J:Stop Valve Jump to
Chapter
Chapter 1
Shuttle Valves Why Use
Pneumatics?
NITRA shuttle valves automatically select the higher of two inlet pressures and direct that flow to the outlet. Models are available in
nickel-plated brass or anodized aluminum with push-to-connect or threaded fittings. Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Figure 7K: Shuttle valve Pneumatic Actuator
Chapter 5
Valves for
Bleed Valves Pneumatic
Cylinders
NITRA bleed valves provide a pushbutton to manually release trapped or excess air pressure from a pneumatic system. These nickel-plated Chapter 6
brass valves are available with threaded fittings. Pneumatic
Tubing &
Hose
Chapter 7
Pneumatic
Fittings
Chapter 8
Electro
Are Pneumatic
Pneumatic
Figure 7L: Bleed valve Systems in Action
Components
Compatibl9
Chapter 9
Pneumatic
Electro Pneumatic
System Design
Systems in Action
Considerations
Chapter 10
Energy Efficient
Pneumatic
Pneumatic
System Systems
Design
Considerations
Chapter 11
Pneumatic
Energy Actuator
Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Chapter 7
33
pneumatics Are Pneumatic Components Compatible
Chapter
The industrial pneumatics market is fairly mature. While there continues to be new developments and technologies, many of the tried and
true core products have been around for years. One advantage that this can offer to both system designers and end users is often having
8
several brands of components that are interchangeable with each other. This can allow users the opportunity to shop around and look at more
than one supplier for the same component.
Competition is almost always beneficial to customers because now factors such as price, availability and service can be considered along with
performance when making a buying decision. Check out our Interactive Cross Reference Chart here.
Here are examples of a few components that have interchangeable sources:
Non-Repairable Air Cylinders

Jump to
Type Mount Bore Stroke Bimba Norgren Parker Chapter
(AutomationDirect) Chapter 1
Why Use
Pneumatics?
Double
Pivot 3/4” 6” A12060DP 046-DP RLC06A-DAP-AA00 0.75DPSRx6.0
Acting Chapter 2
Pneumatic Circuit
Symbols Explained
Single
Nose 7/8” 3” A14030SN 063 — 0.88NSRx3.0 Chapter 3
Acting Understanding
Pneumatic Air
Preparation
Double Double
1-1/4” 10” A20100DD 1210-DP RLE10A-DAD-AA00 1.25PSRx10.0 Chapter 4
Acting End Pneumatic Actuator
Table 8A: Examples of a few components that have interchangeable sources
Chapter 5
Valves for
Pneumatic
Pipeline Valves Cylinders
Chapter 6
Pneumatic
Tubing &
Normal State Thread Control Hose
Pipeline Valves ASCO
w/o power applied Size Voltage (AutomationDirect) Chapter 7
Pneumatic
Fittings
2-way direct acting
normally closed 1/4” NPT 24VDC DVP-3DC2E-24D 8262H007 Chapter 8
solenoid valve Are Pneumatic
Components
Compatible?
2-way direct acting
normally closed 3/8” NPT 120VAC DVP-3DC3F-120A 8263H232 Chapter 9
solenoid valve Electro Pneumatic
Systems in Action
2-way diaphragm Chapter 10

normally closed 1” NPT 120VAC DVD-2BC6F-120A 8215B050
solenoid valve Pneumatic
System Design
Considerations
2-way stackable Chapter 11
normally closed 1/8” NPT 120VAC DVP-2CC1C-120A 8280B002
solenoid valve Energy Efficient
Pneumatic Systems
2-way stackable Chapter 12

normally closed 1/8” NPT 120VAC DVP-2CC1C-120A 8280B002 Pneumatic Actuator
solenoid valve vs. Electromechanical
Table 8B: Pipeline Valves Chapter 13

Application
Stories
Chapter 8
34
pneumatics
Are Pneumatic Components Compatible
Compact Air Cylinders

Chapter
8
MFD
Type Bore Stroke Fabco-Air Numatics Parker SMC
(AutomationDirect) Pneumatics
Double Acting 100mm 100mm GND- MACQ- UND- CDQ2A-

H100M100MD-M S100DC7G0100
w/ Magnet SA100X100DB 100X100-S-T SA100-100D-B 100TN-100DZ
Table 8C: Examples of Compact Extruded Body Cylinder
Jump to
Chapter
Chapter 1
Why Use
Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Figure 8A: Compact Extruded Body Cylinder Chapter 6
Pneumatic
Tubing &
Hose
Compatibility Note Chapter 7
Pneumatic
Fittings
Care must be taken when changing brands to verify any possible differences in performance or dimensions. If you can adapt to some
small differences, however, you may often be able to find a less expensive or more readily available component to do the same job as Chapter 8
Are Pneumatic
your current one. Components
Compatible?
Chapter 9
Electro Pneumatic
Systems in Action
Chapter 10
Pneumatic
System Design
Considerations
Chapter 11
Energy Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Chapter 8
35
pneumatics
Working Together…
Electro-pneumatic Systems in Action
In order to perform a task using pneumatics, there needs to be some way to initiate, monitor, and stop the process. This is where a simple
Chapter
9
pneumatic system becomes electro-pneumatic. Electro-pneumatic systems integrate pneumatic and electrical technologies into one system
where the signal/control medium is electrical and the working medium is compressed air. In this type of system, devices like relays, solenoid
valves, limit switches, and PLCs can be used to interface electrical control with pneumatic action. There are basically two areas to focus on with
the electrical side of an electro-pneumatic system: how to start/stop the process and how to know what the system is doing.
Who’s the Boss?

In many electro-pneumatic systems, the device being controlled is an electrically actuated directional control valve. These control valves
supply air pressure to devices like cylinders that will extend or retract a rod when pressure is applied or removed. Built-in solenoids are used to
open and close these valves and are activated with AC or DC voltage signals. Looking at the conveyor configuration below, notice the diverting
conveyor between the two conveyor lines. This diverter is used to return boxes that aren’t filled properly and it is pneumatically raised and Jump to
Chapter
lowered when the selected boxes are in position. In this example, there are a few different ways to control the solenoid air valve responsible Chapter 1
Why Use
for raising and lowering the diverter. Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Pneumatic
Fittings
Figure 9A: Pneumatic diverter belt, down position
Chapter 8
Are Pneumatic
Components
Compatible?
Chapter 9
Electro Pneumatic
Systems in Action
Chapter 10
Pneumatic
System Design
Considerations
Chapter 11
Energy Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Figure 9B: Pneumatic diverter belt, up position

Chapter 9
36
pneumatics
Chapter
The first option is manual control, using a device like a pushbutton. With a single momentary pushbutton and a voltage source, the operator
can determine when the belt will raise or lower by pressing the pushbutton and closing the normally open contacts within. Once closed, the
9
supplied voltage will be provided to the solenoid and the control valve will open allowing air flow to the cylinders. The cylinders will extend
and the belt will raise into the diverting position. When the pushbutton is released, the air flow will stop, the cylinders will retract, and the
belt will lower to its initial position. Although the simplest way to provide electrical control, the manual method requires the operation to be
manned at all times.
Jump to
Chapter
Chapter 1
Why Use
Pneumatics?
Chapter 2
Pneumatic Circuit
Figure 9C: Pushbutton examples Symbols Explained
Chapter 3
Another option for electrical control is the use of relays. When a relay’s coil is energized by an electrical signal it will close or open the Understanding
Pneumatic Air
normally-open or normally-closed contacts within. By connecting the pneumatic control valve to a relay contact and an object detection Preparation
device, like a photo eye, to the relay’s coil, the system will activate the pneumatic action automatically. Once a box is in position and detected Chapter 4
Pneumatic Actuator
by the photo eye, the relay’s coil will energize and in return a voltage signal will be sent to the control valve. Once again the cylinders will (Air Cylinder) Basics
extend and the belt will raise. Relays are available in both electromechanical and solid state versions and in this scenario, a time delay relay
Chapter 5
or latching circuit may also be needed to ensure the box has traveled the length of the belt before the belt is retracted. Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Pneumatic
Fittings
Chapter 8
Are Pneumatic
Components
Compatible?
Chapter 9
Electro Pneumatic
Systems in Action
Figure 9D: Relay examples
Chapter 10
Pneumatic
System Design
Considerations
Chapter 11
Energy Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Chapter 9
37
pneumatics
In a more complex system with numerous valves, relays may become too cumbersome to install, modify and maintain. This is where
PLCs reign supreme. PLCs can not only handle many logical inputs and control outputs, but they can also easily integrate timing
Chapter
9
functions, sequential operations, alarming, remote visibility, etc. into a pneumatic application. With a PLC, the photo eye is wired to an
input module and the control valve is connected to an output module. Logic code within the PLC will determine when to activate the control
valve output using the transitions in the photo eye input. Additional code can also be written for latching functions, alarming,
data logging, etc. For more information on PLCs and PLC programming, see The PLC Handbook – A Practical Guide to Programmable
Logic Controllers eBook on our library site.
Jump to
Chapter
Chapter 1
Why Use
Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Figure 9E: PLC example (Productivity2000) Preparation
Chapter 4
That Makes Sense! Pneumatic Actuator
Another important component of electro-pneumatic systems is feedback. Feedback devices inform the operator of system status and whether Chapter 5
or not the requested task has been completed, or even attempted. Three important things to know when it comes to pneumatic systems are Valves for
Pneumatic
pressure, flow and position. Cylinders
Chapter 6
Pneumatic
Pressure in pneumatics is similar to voltage in electricity. They both represent the potential energy available in the system. The difference in Tubing &
pressure from one point to another is what causes air flow in pneumatics the same way the voltage difference between two points causes Hose
Chapter 7
current flow in electricity. So, the amount of pressure available is an extremely important component. To measure this pressure, pressure Pneumatic
Fittings
transmitters or pressure switches can be installed in the pneumatic circuit. Some applications, like pneumatic stamps, may also use pressure
sensors to detect the optimal pressure applied during the stamping operation. Chapter 8
Are Pneumatic
Components
Compatible?
Chapter 9
Electro Pneumatic
Systems in Action
Chapter 10
Pneumatic
System Design
Considerations
Chapter 11
Energy Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Figure 9F: Pressure sensor example

Chapter 9
38
pneumatics
Flow is also important as it represents the speed at which cylinders extend and retract. In other words, at a given pressure, flow rate
determines the rate of energy transfer (i.e., horsepower) the system will supply. This can be monitored using flow sensors and controlled
Chapter
9
using flow control valves. Flow switches will inform you if the air flow reaches a set value and flow transmitters will tell you the exact
flow value detected. Position tracking in electro-pneumatic systems, like our conveyor, is accomplished by tracking the position of cylinder
pistons or the devices they are connected to. Many cylinders have magnets built in to the piston that allow magnetic switches to detect
the position of the cylinder. These switches can be mounted directly to the cylinder housing, as seen below, and detect when the piston
is fully extended or retracted.
Jump to
Chapter
Chapter 1
Why Use
Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Figure 9G: Typical installation of a position sensor on a cylinder with a magnetic piston Pneumatic Air
Preparation
Another option with position detection is to use proximity or limit switches external to the cylinder. Proximity switches will detect Chapter 4
Pneumatic Actuator
position using magnetic, ultrasonic, inductive or capacitive means and limit switches will determine position by physically contacting the (Air Cylinder) Basics
device being moved. Various types of limit switches are available, including ones with plungers, levers, rollers, and rods. Looking at the Chapter 5
conveyor example, the position of the diverter belt is determined by using a proximity switch mounted underneath the conveyor. When Valves for
Pneumatic
the belt is lowered it moves into the range of the proximity switch. The switch then sends a signal to the controller indicating that the diverter Cylinders
is in its lowered position. Chapter 6

Pneumatic
Tubing &
Hose
Chapter 7
Pneumatic
Fittings
Chapter 8
Are Pneumatic
Components
Compatible?
Chapter 9
Electro Pneumatic
Systems in Action
Chapter 10
Pneumatic
System Design
Figure 9H: Proximity sensor example Considerations
Chapter 11
Energy Efficient
Pneumatic Systems
A limit switch with a plunger could have also been used to determine the
Chapter 12
conveyor position but limit switches have mechanical components that can wear Pneumatic Actuator
out over time and in applications with frequent movement, a solid state device vs. Electromechanical
is preferred. If you would like more information on object detection devices and Chapter 13
Application
how to use them, please visit our Object Detection video cookbook series. Stories
Chapter 9
39
pneumatics
Additional Options
There are many other devices available that can make your pneumatic system safer and more intelligent. One example of a safety device in
Chapter
9
pneumatics is the soft start valve. This valve is used inline with air preparation components and it will slowly ramp up the system pressure
to the desired level when its solenoid is energized. This way when a pneumatic system is coming online, the initial pressure will slowly
increase in the system ensuring cylinders and other components do not slam into position. The slamming can damage components or injure
any personnel unaware that the system is going live. Once the system pressure has reached the set point, these valves become transparent to
the system. Also, soft start valves can depressurize the downstream pressure when the solenoid is de-energized. This can be tied to an Estop
circuit to automatically dump the downstream pressure when an emergency is present.
Jump to
Chapter
Chapter 1
Why Use
Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Pneumatic
Fittings
Chapter 8
Are Pneumatic
Components
Compatible?
Adding an electro-pneumatic transducer to a pneumatic system will also provide more control of system pressure. These devices, often called Chapter 9
I/P converters, will take a current signal and convert it to a proportional pneumatic pressure value. I/P converters are used to achieve accurate, Electro Pneumatic
Systems in Action
repeatable pressure when precision control of pneumatic actuators/operators, pneumatic valves, dampers, vanes, etc. is required.
Chapter 10
Pneumatic
A recent advancement in electro-pneumatics is the fieldbus-networked valve manifold. This new technology allows pneumatic manifolds to System Design
Considerations
be monitored and controlled over industrial Ethernet networks. When used with PLCs, it allows the controller to more efficiently turn valves
Chapter 11
on and off without the usual hardwiring, and to gather I/O data from sensors, relays, individual valves, or other I/O devices via communication Energy Efficient
Pneumatic Systems
networks. With Ethernet technology, these manifolds can also integrate an on-board web server, which can make the manifold accessible
to any standard web browser. Email capability is also possible and allows the manifold to send email messages containing information Chapter 12
Pneumatic Actuator
like diagnostic data when triggered. vs. Electromechanical
If you would like to see more about the options available for electro-pneumatic systems, please check out our in-depth pneumatic webinar Chapter 13
Application
series which explores our available pneumatic components and includes a demonstration on electrical control and monitoring. Stories
Chapter 9
40
pneumatics Pneumatic System Design Considerations
Pneumatic systems as a whole can be simple, but this simplicity can be deceptive when it comes to selecting components. For instance,
Chapter
there are thousands of types, sizes, and variations of cylinders and valves, from off-the-shelf versions to custom designs. The sheer number
10
of choices can be overwhelming, especially when options such as sensors are added to the mix. So how do you know what is right for your
application? Well since every application is different, that’s a hard one to answer. But the following section discusses a few considerations that
can be helpful when selecting the right components for your pneumatic system. And taking the time to choose the right components for the
job will ensure good performance, lower expenses, improve cycle rates, and prolong equipment life.
Compressed Air Supply

Adequate sizing of compressors and feed lines is the first place to start to ensure proper system operation. Consistent plant air pressure with
suitable flow allows pneumatic devices to operate as designed, and low or varying air pressure can negatively impact the final product and
overall machine sequence. For example, a manufacturing plant was experiencing low air pressure in its facility at the end of the day shift,
causing one of the machines to fault due to low air pressure in its pneumatic actuation system. The problem was found to be high volume Jump to
air consumers nearby, namely blow guns being used to clean machines at the end of each day. Insufficient capacity at the air compressor, or Chapter
Chapter 1
undersized plant air supply tubing and piping is a common issue and one to look out for. If air consumption is a major concern for your factory, Why Use
check out our Interactive Air Consumption Calculator here. Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Pneumatic
Fittings
Chapter 8
Are Pneumatic
Components
Compatibl9
Chapter 9
Electro Pneumatic
Systems in Acti
Chapter 10
Pneumatic
System Design
Considerations
Figure 10A: Basic Air Prep System Chapter 11
Energy Efficient
Pneumatic Systems
Air Flow Control
Once consistent and correct pneumatic system air pressure and flow is established, plant supply air should be connected to a manual, Chapter 12
Pneumatic Actuator
lockable air dump valve at each use point. This lockout, tag-out capability is important for isolating a machine—or a module of a large vs. Electromechanical
machine—for changeover, maintenance or tooling changes. A filter regulator should also be installed at the air dump valve. The filter Chapter 13
removes dust particles and water that can cause wear and operation problems for pneumatic system components. A regulator is required Application
Stories
to throttle to the design air pressure at the use point, typically 60 to 90 psi, as the plant air supply is usually higher, about 100 to 130 psi.
Operating at the design pressure as opposed to plant pressure will reduce wear on pneumatic components.
Chapter 10
41
pneumatics
Pneumatic System Design Considerations
Chapter
An electric, soft start valve downstream of the regulator allows air pressure to gradually increase at start-up, preventing sudden banging
or slamming of cylinders at power up. This is especially important if 4-way, 2-position valves are used because a 2-position valve spool
10
maintains its position after power off and the removal of air. When power and air is reapplied, air will return to the cylinder. If all air was
exhausted, no air is available on the other side of the cylinder. This makes speed control with flow controls non-functional.
The uncontrolled speed of the cylinder could cause a high-speed stroke, commonly ending with a bang. When soft start valves are correctly
applied, a machine will typically return to its home position slowly and smoothly at power up.
Lubricators should be used sparingly and only when necessary. Most modern pneumatic components come lubricated from the factory
and do not need oil. However, pneumatic motors on air tools and other equipment do require a lubricator and one should be supplied in
these instances.
Cylinder Types
Jump to
Pneumatic cylinders are a popular way to clamp, position and transfer parts in automated equipment and although there are many Chapter
Chapter 1
types of cylinders, their construction is fairly similar from one to another. If you haven’t already, take a moment and review the Cylinders Why Use
Pneumatics?
section to get a basic understanding of what cylinders are and how they operate. Understanding the basics helps to know how
different applications affect the cylinder and piston rod. Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Pneumatic
Fittings
Chapter 8
Are Pneumatic
Components
Compatibl9
Chapter 9
Electro Pneumatic
Figure 10B: Typical pneumatic actuators Systems in Acti
Chapter 10
The first step in choosing a cylinder is deciding whether to use the single- or double-acting version. As mentioned previously, Pneumatic
System Design
single-acting cylinders use compressed air to move the load in one direction and double-acting cylinders use compressed air for movement Considerations
in both directions. With single-acting cylinders, air is supplied to only one side of the piston and a spring (or, in some cases, gravity) returns Chapter 11
Energy Efficient
the piston to its original position once air pressure is removed. And while double-acting cylinders use more air (both for the extend and Pneumatic Systems
retract), they are well suited for loads that require both pushing and pulling.
Chapter 12
Pneumatic Actuator
In both cases, force calculations can get complicated. In single-acting cylinders with a spring, the spring force opposing the push or pull vs. Electromechanical
increases as the stroke progresses. And in double-acting cylinders, push and pull forces are not equal, as rod area must be accounted for in
Chapter 13
force calculations. Often, manufacturers’ catalogs will list push and pull values for both double-acting and single-acting cylinders, with and Application
Stories
without springs, in order to simplify these calculations and help with selecting the proper cylinder type. Take a look at our Interactive Bore
Calculator here.
Chapter 10
42
pneumatics
Chapter
10
Figure 10C: Interactive Cylinder Bore Calculator

Jump to
Chapter
Chapter 1
Why Use
Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Cylinder Sizing Valves for
Pneumatic
The load is the primary consideration when determining cylinder type and piston size. The piston area (force factor) multiplied by the Cylinders
Chapter 6
air pressure in the cylinder gives the available force. A general rule is to select a force factor that will produce a force 25% greater than the Pneumatic
load to help compensate for friction and losses. Pneumatic systems are quite forgiving in terms of oversizing, but using components that Tubing &
Hose
are too big adds unnecessary expenses in terms of both purchase price and energy consumption. Chapter 7
Pneumatic
Fittings
The bore size (force factor) determines force at a given pressure. The operating pressure, which in a plant can typically range from 10 to 150
psi, is the first consideration when selecting a bore size. The next step in choosing the bore size is the amount of force that the application Chapter 8
Are Pneumatic
requires. Suppliers often provide charts to assist with calculating bore size. If the bore diameter is between sizes, fluid-power experts Components
Compatibl9
recommend rounding up to the next size. It’s also important to remember the bore diameter squares the thrust delivered. For example,
Chapter 9
a two-inch diameter cylinder has four times the power of a one-inch diameter unit. Therefore, doubling the bore quadruples the thrust. Electro Pneumatic
Systems in Acti
In addition to load, designers must also take into account the speed at which the load will move. When compressed air flows through Chapter 10
a system, there are pressure losses due to friction against the tube wall, flow around bends, and restrictions in valves and fittings (to name Pneumatic
System Design
a few issues). Higher speeds result in greater pressure loss as the air must flow faster through the valves, tubing and ports. Attaining higher Considerations
Chapter 11
speeds also requires that the cylinder deliver more force in a shorter amount of time. A force that exceeds the load by 50% or more Energy Efficient
may be required to reliably move a load at high speeds. For example, a typical air compressor might supply air to a system at 100 psi. In an Pneumatic Systems
application with a slow-moving load, the actual pressure available at the piston might be reduced to no less than 90 psi. With that same Chapter 12
load moving at a much faster rate, the available pressure could drop as low as 70 psi. Pneumatic Actuator
Pressure losses can be remedied by increasing pressure, but this must be done with caution: Too much pressure creates stress on Chapter 13
Application
the cylinder and could possibly damage the cylinder, as well as the load. In these instances, it’s better to go with a larger cylinder. Stories
Also keep in mind that raising system pressure means the compressor must work harder, increasing energy consumption of the overall
pneumatic system.
Chapter 10
43
pneumatics
Cylinder Options
Chapter
Even when a cylinder is sized properly, it may stroke too fast and require use of a flow control, typically by controlling flow of air leaving
10
the cylinder. This also reduces noise problems caused by cylinders banging and reduces rapid exhaust racket. These flow controls are
typically mounted directly to the cylinder, but can also be mounted inline near the cylinder, or at the valve if the hose between the valve
and cylinder is less than about 3 feet.
Specifying cylinders with built-in cushions can help provide long-term performance in high-speed pneumatic motion applications. The
cushions allow a cylinder to stroke at high speed and only slow down near the end of stroke for a quiet, low-impact stop. Adjustable
pneumatic cushions are often the best solution, comprised of specially designed end caps with built-in flow controls. Mufflers can also be
used to quiet cylinder or valve exhaust noise, and they are often a simple and low cost solution.
Jump to
Chapter
Chapter 1
Why Use
Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Figure 10D: Flow control valves Valves for
Pneumatic
Cylinders
Cylinder position switches are extremely helpful in sequencing operations and prevent starting the stroke of one cylinder before the Chapter 6
Pneumatic
previous cylinder’s stroke is complete. Using timers to control a sequence instead of position sensors should be avoided in this and most cases. Tubing &
One stuck or slow cylinder during an automated sequence can cause a machine crash, costing much more than the cost of buying, Hose
Chapter 7
installing and programming end-of-stroke sensors. Pneumatic
Fittings
Chapter 8
Are Pneumatic
Components
Compatibl9
Chapter 9
Electro Pneumatic
Systems in Acti
Figure 10E: Cylinder switches
Chapter 10
Pneumatic
Control Valves System Design
Considerations
Once the cylinders are selected, you should now have a good idea of the flow rate and pressure of compressed air needed. With this Chapter 11
Energy Efficient
information, control valves can be selected. Items to consider in valve selection are size (flow capacity), type and actuation method. Pneumatic Systems
Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Chapter 10
44
pneumatics
Valve Type
Chapter
Choosing the right type of valve for the job required is not as difficult as it may seem. For cylinder control, the simplest method is to use
10
a 3 way valve for a single acting cylinder and a 4 way valve for a double acting cylinder. Systems can be much more complex if needed, but
let’s focus on a basic system for now. The form factor of the valve can vary a great deal and many people have a variety of preferences.
It’s usually best to make sure the valve has the needed performance characteristics before locking into a particular form factor.
Valve Sizing
Now that the function of the valve has been determined, look at the required flow capacity. The usual first step is to use the air cylinder
bore, stroke and cycle rate to determine a flow rate in standard cubic feet per minute (SCFM). Many valve suppliers will list a flow rate
at a particular inlet pressure and pressure drop. Others will list this value as a factor Cv, which has no units. For a more thorough
explanation, check out our Interactive Cv Calculator here. A simple thing to remember is that a larger Cv value will allow a higher flow rate
of air through the valve. Key points to remember in valve sizing are that undersized valves may restrict flow and not allow a system to work Jump to
Chapter
properly. Oversized valves often cost more and will use more air. Keep in mind that air consumption is a major portion of the expense for Chapter 1
a pneumatic system. If air consumption is a major concern for your factory, check out our Interactive Air Consumption Calculator here. Why Use
Pneumatics?
Valve Actuation Chapter 2

Pneumatic Circuit
Symbols Explained
How will the valves be operated? Manual valves could be push button, lever or foot pedal activated. The more common method is to use
electric solenoids to operate the valve. Solenoids are available in both AC and DC in a variety of voltages to fit just about any need. Match Chapter 3
Understanding
the solenoids up with your electrical control system. In less common situations, an air piloted valve may be required. When air pressure Pneumatic Air
Preparation
is applied to a pilot port, the valve switches. This is a good way to switch very large valves while using very electrical power – use a small
Chapter 4
solenoid valve to send air to the pilot port of the large valve. Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Pneumatic
Fittings
Chapter 8
Are Pneumatic
Components
Compatibl9
Chapter 9
Electro Pneumatic
Systems in Acti
Chapter 10
Pneumatic
System Design
Considerations
Chapter 11
Energy Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
These are just a few of the many items to consider when designing a successful pneumatic system. Other factors, such as energy
Chapter 13
efficiency, can affect overall system design as well. But regardless of the design, watch out for the common issues and always be sure to supply, Application
prep and distribute the air properly. When properly applied, your pneumatic devices and actuators will have a long life with limited Stories
operational issues along the way, and with minimal required maintenance.
Chapter 10
45
pneumatics Energy Efficient Pneumatic Systems
Chapter
11
Jump to
Reducing energy consumption is a priority in almost every manufacturing plant and industrial facility, as no company can afford to throw Chapter
money away using machines and processes that waste energy. Because pneumatic systems are abundant throughout manufacturing and Chapter 1
Why Use
account for a large share of a plant’s power costs, it is extremely important that they run efficiently. Pneumatics?
Chapter 2
Unfortunately, many users have the mindset that pneumatic systems are inherently inefficient, therefore overlooking opportunities for Pneumatic Circuit
energy savings. In addition, some manufacturers of industrial equipment and robots tend to focus on ensuring the pneumatic systems Symbols Explained
perform their intended functions, and in the process neglect efforts to reduce operating costs. Fortunately, there are ways to improve Chapter 3
the energy efficiency of pneumatic systems using tactics that range from better engineering decisions in the design stage, to adjustments Understanding
Pneumatic Air
and maintenance on existing systems. And by optimizing these systems, companies can reduce their compressed-air energy consumption by Preparation
Chapter 4
anywhere from 20 to 35%. Pneumatic Actuator
Minimize Leaks Chapter 5

Valves for
Leaks are common and expensive in pneumatics systems. Statistics from the U. S. Department of Energy show the average manufacturing Pneumatic
Cylinders
plant loses 30 to 35% of its compressed air due to leakage. The good news is many leaks can be prevented or repaired. Chapter 6
Pneumatic
Tubing &
Of the many points between the compressor and Hose
the load where leaks occur, valves and seals are Chapter 7
Are Pneumatic
Pneumatic
two main areas for improvement. Deteriorated Components
Fittings
Compatible?
seals should be the first area to examine
Chapter 8
and remedy. Environmental conditions, such as Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
temperature, moisture content and lubrication, all Compatibl9
contribute to the leakage rate of a seal. Pneumatic Chapter 9
Pneumatic
Electro Pneumatic
systems in areas with high contamination risk System Design
Systems in Acti
Considerations
can benefit significantly from an investment in
Chapter 10
resilient seals like Viton, Teflon or polyurethane. Pneumatic
System Design
Consideration
Another consideration with leakage is proper Chapter 11
valve selection. Selecting the best valve for the job Energy Efficient
Pneumatic Systems
can prevent unnecessary leakage and unnecessary
Chapter 12
cost. Certain valve designs, such as lapped-spool valves with metal seals, have inherent internal leakage that is constant while air is supplied ApplicationActuator
Pneumatic
to the valve. Nonetheless, it’s important to note that lapped spool and metal sleeve valve air consumption doesn’t vary during operation. On Stories
the other hand, installing valves with soft seals can significantly lower leakage on the front end, but a soft seal produces hundreds of times Chapter 13
more leakage than the lapped spool-and-sleeve valve during an open crossover when the valve shifts. In this case, it is important to look at Application
Stories
total air leakage over the whole operation being performed in order to determine which type of valve will optimize the energy usage.
Chapter 11
46
pneumatics
Energy Efficient Pneumatic Systems
Compressor Enhancements
Chapter
After fixing leaks, compressors are the next biggest area for improvement. U.S. Dept. of Energy reported that manufacturers spend over
11
$5 billion each year on energy for compressed air systems. This shouldn’t be surprising since they form the backbone of the pneumatic system.
Manufacturers that optimize their compressed air supply systems have seen significant reductions in their energy consumption. Detailing
the methods for increasing compressor efficiency is beyond the scope of this chapter. However, the Dept. of Energy offers guidelines for
determining the cost of compressed air in a plant, as well as tips on how to reduce compressor energy usage.
Jump to
Chapter
Chapter 1
Why Use
Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Optimizing Pressure Chapter 6
Pneumatic
As compressed air flows through typical circuits, air pressure drops due to changes in demand, line and valve-flow resistance, and other Tubing &
Hose
factors. But many of these losses are simply because the distance between the compressor or supply point and the actuator is longer than Chapter 7
Are Pneumatic
Pneumatic
necessary. Designs that use the shortest tubing possible can reduce energy consumption as well as cycle times. Typically, tubing between Components
Fittings
control valves and cylinders should be less than 10-ft long. Longer lengths require more pressure so that force, speed, and positioning Compatible?
Chapter 8
capabilities aren’t compromised. Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
Compatibl9
Another way to eliminate unnecessary consumption is ensuring actuators use only the pressure needed to perform a task. Sometimes,
Chapter 9
operators on the plant floor increase supply pressure in the belief that it improves performance. However, all this does is waste energy Pneumatic
Electro Pneumatic
System Design
Systems in Acti
and money. Installing sensors that monitor pressure, and pressure regulators that maintain correct settings, can keep pressure within Considerations
the minimum and maximum parameters. Many engineers also design systems that deliver more pressure than needed to the actuator. Chapter 10
Pneumatic
Regulators that control pressure to individual pneumatic cylinders will increase energy efficiency, in many instances generating savings System Design
Consideration
of up to 40%. Chapter 11
Energy Efficient
Pneumatic Systems
Chapter 12
ApplicationActuator
Pneumatic
Stories
Chapter 13
Application
Stories
Chapter 11
47
pneumatics
Regulate the Return Stroke

Chapter
Another way to conserve energy is by supplying the correct pressure for an actuator’s return stroke. Most applications only move a load in
11
one direction. However, many machines inefficiently use the same pressure for both the working and return strokes.
For example, a material-handling system that pushes boxes from one conveyor to another needs high cylinder force only in one direction.
The working stroke may demand 100 psi to move a box, but the low-force return stroke only requires 10 psi. Using the same pressure in
both directions wastes energy. Reducing the pressure on the return stroke saves 90% of the volume of compressed air. Because that
conserves compressed air, a lot of energy is saved over the thousands of cycles that the action is performed. And regulating air pressure
not only saves energy, it also minimizes wear on the pneumatic and related components. By reducing pressure for the extract stroke to
only what is needed, the machine is not subjected to unnecessary vibrations and shock.
Another option for improving efficiency in processes with shorter strokes is to use a spring return actuator. The control valve in a spring
return actuator ports the pressure (using the compressed air) for the working part of the stroke, and then exhausts the air. For the Jump to
Chapter
return stroke, the spring—or sometimes merely the weight of the mechanism—takes the cylinder back to the starting position. Chapter 1
Why Use
Pneumatics?
A typical case where single-acting, spring-return cylinders can reduce energy demand involves presses. In this type of application, a
cylinder pushes two items together such as a bearing into a housing, or a plug into a hole. The job demands a significant amount of force Chapter 2
Pneumatic Circuit
to press the parts together, but only a small amount to retract. This makes it a good candidate for energy savings by eliminating the Symbols Explained
return-stroke air consumption completely since the spring return can provide the force needed for retraction.
Chapter 3
Understanding
Pneumatic Air
Proper Sizing Preparation
Chapter 4
It’s important to take the time upfront to correctly size the Pneumatic Actuator
pneumatic system’s components because each component’s
size affects other parts of the system. Buying smaller control Chapter 5
Valves for
valves may save money on the purchase price, but they will Pneumatic
Cylinders
be more expensive over time. Smaller control valves will
Chapter 6
require the air compressor to work harder simply to get Pneumatic
Tubing &
the proper pressure to the actuators, creating a long-term Hose
demand for more energy. Chapter 7
Are Pneumatic
Pneumatic
Components
Fittings
Another common problem comes from oversizing the Compatible?
cylinders more than necessary. Some oversizing is necessary Chapter 8

Electro
Are Pneumatic
Pneumatic
to compensate for pressure fluctuations and air losses; Systems in Action
Components
Compatibl9
however, components that are far too large account for one Chapter 9
of the biggest energy losses in a pneumatics system. Pneumatic
Electro
Systems
Pneumatic
System Design
in Acti
Considerations
For instance, a 3-inch cylinder requires more than double the volume of air of a 2-inch cylinder. However, this much extra capacity may Chapter 10
Pneumatic
not be needed. To avoid grossly oversizing, it’s important to remember most loads and speeds require only 25% additional capacity to System Design
Consideration
ensure correct operation. By selecting the right amount of oversizing, cylinder efficiency can be improved by as much as 15%. When
Chapter 11
factoring in the number of cylinders that will operate thousands of times over their life span, the savings from right sizing becomes significant. Energy Efficient
Pneumatic Systems
To assist with the many calculations and considerations that go into properly sizing components—such as if the load is rolled or Chapter 12
lifted—there are software packages, online calculators, and even an iPhone app that can assist with component sizing. By spending a little ApplicationActuator
Pneumatic
Stories
more time understanding the system’s true requirements, the savings can be substantial.
Chapter 13
Application
Stories
Chapter 11
48
pneumatics
Chapter
11
Jump to
Chapter
Chapter 1
Why Use
Pneumatics?
Chapter 2
Hit the ‘OFF’ Switch Pneumatic Circuit
Symbols Explained
Shutting down a machine when it’s not working seems like an obvious way to save energy. While some elements of a system, such as air
Chapter 3
bearings, can require pressure even when the machine is off, the required compressed airflow is usually much less than that needed during Understanding
Pneumatic Air
normal operations. However, many installations have no automatic way to reduce or stop airflow to idle machines. Reduced staffing often Preparation
means that manufacturers can no longer send maintenance workers to manually turn off air to specific machines. Or sometimes workers Chapter 4
Pneumatic Actuator
don’t understand that an idle machine requiring pressure only needs a fraction of the pressure required during operation. These facilities (Air Cylinder) Basics
can benefit from an automatic air reduction control package to lower the air pressure to necessary levels when the machine isn’t
Chapter 5
working. Typically, the cost of these devices is recovered within a few months. Valves for
Pneumatic
Cylinders
Save Energy, Save Money Chapter 6

Pneumatic
Tubing &
In the past, businesses were mainly concerned only with their pneumatic systems performing their job correctly. Little thought was put Hose
into correctly sizing components and making sure that only the pressure required was used. However, today’s businesses can’t afford to Chapter 7
Are Pneumatic
Pneumatic
waste energy in any area of the plant. The good news is that with some time dedicated to determining the actual requirements of the Components
Fittings
Compatible?
pneumatic system and selecting the right components, plants can expect improvements in both energy efficiency and productivity.
Chapter 8
Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
Compatibl9
Chapter 9
Pneumatic
Electro Pneumatic
System Design
Systems in Acti
Considerations
Chapter 10
Pneumatic
System Design
Consideration
Chapter 11
Energy Efficient
Pneumatic Systems
Chapter 12
ApplicationActuator
Pneumatic
Stories
Chapter 13
Application
Stories
Chapter 11
49
pneumatics Pneumatic Actuator vs. Electromechanical
In materials handling and assembly there are many ways to move an item from one location to another. Conveyors are one way and
are widely used, but they can only move objects in a fixed path, limiting their use in more precise manufacturing applications.
Chapter
12
When more accuracy is required than a conveyor can deliver, such as when the part orientation or alignment needs to be changed, a
pick-and-place system is often used. The most common pick-and-place systems employ either pneumatics or electromechanics, with
hybrid electro-pneumatic systems also an option in some applications. The question then becomes what system is the best for each
application, taking into consideration multiple factors including cost, complexity, performance and maintenance.
Picking the Right Pick-and-Place

In regards to complexity and performance, one should consider the amount of movement(s) that must be performed, the required
accuracy of the placement, the weight of the objects to be lifted, the shape of the parts, and the distance they must travel. In general,
jobs with complicated movements requiring a high level of accuracy need more expensive electromechanical pick-and-place systems.
If the application has a fixed travel path and doesn’t need repositioning or multiple positioning, a pneumatic pick-and-place system is Jump to
often the best choice. Chapter
Chapter 1
Why Use
Hybrid systems use electrical components at the front end, and a pneumatic end effector to handle the part or object. These systems Pneumatics?
are more expensive than pneumatic solutions and less costly than electromechanical systems, and can be the best option for some Chapter 2
applications as they combine the economy of pneumatics with the speed and accuracy of electromechanical systems. Pneumatic Circuit
Symbols Explained
When Pneumatics are Better Chapter 3

Understanding
Pneumatic Air
Although initial cost is often the driving force for using pneumatic pick-and-place systems instead of electromechanical solutions, it’s Preparation
not the only reason, as seen in the Table below. Chapter 4
Pneumatic Actuator
Advantages of Pneumatic Pick-and-Place Pneumatic devices have a greater force density than
Chapter 5
many electromechanical solutions, which enables
Over Electromechanical Systems Valves for
them to be a smaller and lighter, lowering space Pneumatic
Cylinders
• Much lower initial cost needs and energy costs. They can also be installed Chapter 6
Pneumatic
• Higher force density without complex components like controllers, as their Tubing &
• More compact in most cases

operation is simpler with a single path of travel. In Hose
Chapter 7
applications with contaminates, such as possible Are Pneumatic
Pneumatic
• Use a safer energy source, compressed air as opposed to electricity
splashes, electromechanical systems pose more Components
Fittings
Compatible?
• Better for wet or corrosive areas danger and are more likely to fail. Furthermore, Chapter 8
Electro
Are Pneumatic
Pneumatic
• Simpler installation, particularly with respect to programming electromechanical pick-and-place systems for these Systems in Action
Components
types of applications usually require specialized Compatibl9
• Easier to maintain due to overall simpler operation Chapter 9
certifications and have a relatively small pool of Pneumatic
Electro Pneumatic
• Familiar learning method for younger students System Design
vendors, thus making them quite expensive. Systems in Acti
Considerations
Table 12A: Advantages of Pneumatic Pick-and-Place Systems Chapter 10

Pneumatic
System Design
Considerations
Pneumatic systems are not only safer in wet or corrosive environments, they can also withstand numerous cleanings. The pneumatic
Chapter 11
devices can be mounted close to the process while the associated electronics are housed in a cabinet well away from possible damage, Energy Efficient
Pneumatic Systems
simplifying installation and maintenance. Moreover, since controls for a pneumatic system are typically smaller than servo drives, internal
space requirements in the control cabinet are reduced. Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Chapter 12
50
pneumatics
Pneumatic Actuator vs. Electromechanical
Build or Buy?
When the decision is made to implement a pneumatic system, the next choice is to buy an off-the-shelf system or to build one
Chapter
12
using cylinders, valves and end effectors. A preconfigured system will be in operation faster as it comes with all components
pre-assembled and tested. Designing and building a custom system will take more time up front, will cost less in terms of purchased parts
and will result in an optimal fit for the application.
Custom pneumatic pick-and-place systems can be built in a variety of configurations using standard components, which are assembled to
produce different linear and rotary motion actions. A basic system can be built using primarily off-the-shelf components at a very
reasonable cost. Nevertheless, designing a pick-and-place system requires a certain amount of engineering skill.
Pneumatic pick-and-place systems rely on cylinders for mechanical movement in either a linear or rotary direction. Round body cylinders
are the least expensive option but they require mechanical guides that are usually custom machined for the particular application.
As such, they may be the best choice for a company that can perform machining in-house. For those without in-house machining Jump to
Chapter
capabilities, guided-rod extruded-body cylinders are a good choice even though they can be up to five times as expensive as their Chapter 1
Why Use
round body counterparts. Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Are Pneumatic
Pneumatic
Figure 12A: Guided cylinders can simplify installation in a pick-and-place application Components
Fittings
Compatible?
Rotary actuators are used with cylinders to perform non-linear, twisting movements; they can flip, tilt or turn a part or an object. For Chapter 8
Electro
Are Pneumatic
Pneumatic
example, a rotary actuator is used on one end of a vertical axis, with a gripper on the other end. This enables the actuator to move parts Systems in Action
Components
Compatibl9
in an arc motion, instead of moving the object up and across in separate movements. It should be noted these actuators typically don’t Chapter 9
rotate more than 270 degrees. Pneumatic
Electro Pneumatic
System Design
Systems in Acti
Considerations
Readily available pneumatic cylinders are generally limited to about 2500 pounds of available thrust, but multiple cylinders can Chapter 10
Pneumatic
be combined into a very powerful pick-and-place system. These cylinders and other components come in a wide range of materials: System Design
Considerations
nickel-plated brass, aluminum, steel and stainless steel. Designers should select the appropriate material depending on loads,
Chapter 11
environmental conditions and cost constraints. Energy Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Chapter 12
51
pneumatics
Stroke Length Considerations

Chapter
The stroke length determines how far the pneumatic device can move. Single-acting cylinders have limited extension resulting from the space
12
needed for the compressed spring. Therefore, single-acting cylinders are best suited for applications that only need approximately 6 inches
(150 millimeters) of stroke length or less.
Since double-acting cylinders don’t use a spring return, stroke lengths for this design are generally available up to 24 inches (600 mm) in most
popular bore sizes. For travel distances longer than 24 inches, there are a number of different rodless cylinder designs that work very well in
pick-and-place systems.
Speed Control Concerns

While pneumatic pick-and-place doesn’t offer the speed control and wide range of motion found with electromechanical systems, they
can deliver an often acceptable level of speed control by using valves. Flow control or needle valves are used to control the speed of the Jump to
Chapter
pneumatic pick-and-place device by regulating the air flow to the actuator. Overall system sizing of valves, tubing and actuators will have
Chapter 1
an effect on achievable speed range, and greater care should be used if speed is critical. Why Use
Pneumatics?
Grippers and Vacuum Device Deployment Chapter 2

Pneumatic Circuit
Symbols Explained
The end effector that picks up the object in a pick-and-place system can be pneumatic grippers or vacuum suction cups both of which are
usually lighter, smaller and less expensive than electric grippers. Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Are Pneumatic
Pneumatic
Components
Fittings
Compatible?
Chapter 8
Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
Figure 12B: Pneumatic powered options for placing product Compatibl9
Chapter 9
Pneumatic
Electro Pneumatic
System Design
Pneumatic grippers work well for applications requiring high speeds or a high gripping force. While they don’t offer the force and Systems in Acti
Considerations
positioning attributes of electric grippers, pneumatic grippers can be adjusted by using a control valve or an analog proportional Chapter 10
Pneumatic
pressure valve to change pressure and thus gripping force. System Design
Considerations
The initial cost of suction cups is low, and they come in a variety of sizes. Suction cups are a good choice for delicate products, such as Chapter 11
Energy Efficient
food and glass, and for flat objects like paper and sheets of metal. While they work for some high-intensity applications, the operational Pneumatic Systems
cost of the required vacuum generators may be prohibitive for systems with just a few cups. For inexperienced users, suction cups
Chapter 12
can also be tricky to implement. Selecting the right size and amount of suction is often more of an art than a science, and determining the Pneumatic Actuator
size and suction of the cups is often an exercise in trial and error unless considerable experience has been gained in similar applications.
Chapter 13
Application
Stories
Chapter 12
52
pneumatics
Reducing Total Cost of Ownership

One of the complaints about pneumatic pick-and-place is relatively high operating costs compared to electromechanical systems
Chapter
12
because they use compressed air. Most pick-and-place systems will operate in settings where compressed air is already being used for
other purposes, and several steps can be taken to mitigate air usage. One way to reduce costs is by mounting the pneumatic control
components near the point of operation to minimize air line lengths. Locating the valving close to the actuators and using appropriate
cylinder and valve combinations can reduce the required air volume by up to 35 percent. In addition, using modern components that are
made to reduce leakage and utilizing improved lubricants that operate across a wider temperature range, will extend the life of actuators
and valves in your system which in turn reduces the costs of maintenance and replacement. If you would like more tips on making your
pneumatic system energy efficient, see the Energy Efficient Pneumatic Systems chapter in this eBook.
The Choice is Yours

There are some misconceptions and outdated ideas about pneumatics that can needlessly drive up the cost of pick-and-place by Jump to
Chapter
relegating users to higher priced electromechanical systems. When just two positions per axis of motion are required, and when very Chapter 1
Why Use
high speed and extreme precision aren’t required, pneumatic pick-and-place systems will usually be a simpler and less expensive Pneumatics?
option. And while pneumatic pick-and-place systems have been used for decades, over time they have been improved with technological
Chapter 2
advances making these time-tested systems a viable choice for many applications. Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Are Pneumatic
Pneumatic
Components
Fittings
Compatible?
Chapter 8
Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
Compatibl9
Chapter 9
Pneumatic
Electro Pneumatic
System Design
Systems in Acti
Considerations
Chapter 10
Pneumatic
System Design
Considerations
Chapter 11
Energy Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Chapter 12
53
pneumatics Application Stories
Want some examples of what people are doing with pneumatics? You’re in luck, we have a full collection of Application Stories on our
Chapter
application stories on our website. For your convenience we took the time to list some of our favorites on the next few pages. You can see a
13
preview below and then pick the ones that look the most interesting to you. Just remember that there is a lot more where these came from.
Pneumatics Improve
Ridgeline Machine’s Equipment
Jump to
Chapter
Chapter 1
Why Use
Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Riada Equipment Solves Understanding
Pneumatic Air
Difficult Packaging Problem

Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Are Pneumatic
Pneumatic
DIY Pneumatic Saw Clamp Components
Fittings
Compatible?
Chapter 8
Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
Compatibl9
Chapter 9
Pneumatic
Electro Pneumatic
System Design
Systems in Acti
Considerations
Chapter 10
Pneumatic
System Design
Considerations
Chapter 11
Pneumatic
Energy Actuator
Efficient
DIY Halloween Pneumatic Systems

Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Chapter 13
54
pneumatics
Application Stories
Pneumatics Improve Ridgeline Machine’s Equipment

Ridgeline Machine Design, LLC (RMD), founded in 2012, is primarily a packaging machinery producer, and the company’s owners have
over 40 years experience designing and building custom machinery. RMD builds packaging machinery for a variety of applications
Chapter
13
for product placement into AFM, FOL, HSC, RSC cases or trays, and they have also branched out into robotics and machinery for
consumer cooler production.
Ridgeline Machine made extensive use of pneumatics when building a low-cost, small-footprint,
portable traymaker to replace a manual process for one of their customers.
Some of the packaging equipment they design and build includes wraparound side-, end- and bottom-loading case packers in many
configurations. RMD also builds case erectors, bag-in-box equipment, case sealers and traymakers.
Engineered Equipment
Jump to
RMD has hundreds of installations in several industries including baking, food, dairy, personal care, chemical and others. Chapter
Chapter 1
RMD designs packaging equipment for products such as coffee, construction adhesives, aerosol, spices, and cartoned and canned food. Why Use
Pneumatics?
Their equipment handles products housed in configurations such as chipboard trays and cartons, corrugated trays, plastic bottles,
gable-top cartons, fiberboard caulking tubes, semi-rigid bags, and steel or plastic cans and tubs. Chapter 2
Pneumatic Circuit
Symbols Explained
Their packaging equipment typically handles from 10 to 50 cases per minute depending on the application, and they offer a case sealer
Chapter 3
capable of speeds of up to 114 cases per minute. RMD equipment typically has an open design for easy operation, quick maintenance Understanding
and simple adjustment. Pneumatic Air
Preparation
Chapter 4
For example, one of their case erectors builds regular, slotted-case, all-flaps-meet boxes with hot melt closure, and it can be adjusted for Pneumatic Actuator
a wide range of box sizes using just two hand wheels. Another example is a case packer used where case sealing with pressure-sensitive
tape is needed. This flexible machine can be changed over in 15 minutes or less. Some case erectors are designed for many SKU changes Chapter 5
Valves for
and can change over in two minutes. Pneumatic
Cylinders
Chapter 6
Their bottom-load case packer works well for applications where a traditional drop-case packer is a poor choice due to possible product Pneumatic
breakage during the loading cycle. The machine’s design provides a gentle bottom-up feature which results in greatly reduced shock to Tubing &
Hose
the product as it’s placed into the case. Chapter 7
Are Pneumatic
Pneumatic
Components
Fittings
Leading motion technologies employed in their machines include pneumatic, servo pneumatic and pure servo, each controlled by various Compatible?
PLC platforms. RMD uses the latest 3D software from SolidWorks to design their equipment. Chapter 8
Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
Compatibl9
Putting Experience to Work Chapter 9
Pneumatic
Electro Pneumatic
For one particular project, RMD started with a list of specifications System Design
Systems in Acti
Considerations
from a manufacturer of custom door locksets and hardware
Chapter 10
based in the western U.S. RMD set out to meet these specs Pneumatic
System Design
using pneumatics in a creative design. Pneumatics was selected Considerations
as the motion control technology for this application due to its Chapter 11
Pneumatic
Energy Actuator
Efficient
low cost, both up front and over time. It is simpler than alterna- Pneumatic Systems
tives such as electromechanical or servos, easy to understand and
Chapter 12
maintain, and straightforward to control and troubleshoot. Pneumatic Actuator
The Model 25 automatic traymaker was developed in partnership Chapter 13

with their customer for this project; the machine assembles trays Application
Figure 13A: Ridgeline Machine Design’s Model 25 Traymaker was designed and Stories
built in partnership with their customer to fulfill specific requirements in terms at a rate of 18 per minute with minimal floor space required and
of space and cost savings at an affordable price (Figure 13A).
Chapter 13
55
pneumatics
Application Stories
Chapter
Traymaker specifications from the client included a small footprint, portability, low cost, easy operation and simple maintenance. The
customer also required a finished tray table with 50-count storage.
13
Because the machine is portable, it operates from 120 VAC to simplify power connection, and to improve safety. Competing machines
typically require 208-230/460 VAC, and are quite a bit more expensive. A small portable footprint is needed due to limited floor space and
the need to move the traymaker often. Low cost was another requirement, and one of the reasons AutomationDirect hardware was chosen.
The customer needed to automate an operation which traditionally required their plant personnel to make the trays by hand.
The production rate was only four trays per minute, and the new machine assembles trays at a rate of 18 per minute, a significant
improvement. The automated machine also freed up four workers who are now performing other tasks to further improve the customer’s
production processes.
The traymaker discharges each tray on its side to help the trays stack better (Figure 13B), whereas most traymakers on the market discharge
Jump to
the tray upright. RMD’s older model traymaker had the tray blank move horizontally before set-up, while this new model has it traveling Chapter
vertically. This required mechanical reorientation of much of the infeed assemblies. Chapter 1
Why Use
Pneumatics?
Chapter 2
Pneumatic Circuit
Symbols Explained
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Figure 12B: Tray output - the completed tray is positioned at the Hose
machine output on its side for easy stacking with other tray Chapter 7
Are Pneumatic
Pneumatic
Components
Fittings
Compatible?
Traymaker Ready for Productio3 Chapter 8
Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
The RMD Model 25 traymaker has a small footprint of approximately 7’H x 5’L x 3’W without the discharge table. The discharge table is Compatibl9
6’L x 4’W. The traymaker is controlled with a wide variety of AutomationDirect hardware including power distribution components, Chapter 9
Pneumatic
Electro Pneumatic
motors, drives, and safety relays and switches. AutomationDirect also provided an extensive pneumatic system starting from the main System Design
Systems in Acti
Considerations
plant connection, proceeding to the flow controls, solenoids, tubing, fittings and cylinders.
Chapter 10
Pneumatic
Much of the product handling and assembly operations are pneumatic. The traymaker includes vacuum pick-off of tray blanks, System Design
Considerations
vertically positioned to save space. The singulated tray blanks are fed into the system using an AC drive powering a motor and a worm Chapter 11
gearbox which drives the tray blank feeding wheels. Pneumatic
Energy Actuator
Efficient
Pneumatic Systems
The vertical, wheel-delivered tray blanks are fed downward to the assembly area, and are then set up by a pneumatic cylinder pressing Chapter 12
Pneumatic Actuator
the blank through tooling. The formed trays are then pneumatically offloaded to the discharge table. vs. Electromechanical
Chapter 13
Application
Stories
Chapter 13
56
pneumatics
Application Stories
Pneumatic Assembly of Trays

Chapter
13
The traymaker pneumatic components start with a 3/8-inch

size filter, regulator and lubricator feeding a bank of valves
operating a mix of round, compact and tie rod cylinders. Air
preparation provides the required high air flow, and also
filters and lubricates the air coming to the machine. The air prep
system includes an electric dump valve to relieve the air supplied
to the control valves when a door is opened or an emergency
stop is pressed. There is also a manual lockable valve on the
inlet, providing the required lockout/tagout functionality when
servicing the equipment.
Jump to
Figure 13C: Air valves and a manifold provide fluid power to the cylinders that feed, Chapter
assemble and stack the trays. Air valves (Figure 13C) control all cylinder and vacuum generator
Chapter 1
operation. The valves are sized for worst case flow for any function Why Use
Pneumatics?
on the traymaker. In this case, 4-way valves were specified to control all the cylinders, as their Cv rating of 0.89 is sufficient for the cylinders
to operate and maintain proper speed. A 3-way valve was selected to operate the pneumatic vacuum generator for the same reason. Chapter 2
Pneumatic Circuit
Symbols Explained
RMD prefers to use manifolds to feed air to the pneumatic control valves, and utilizes an 8-station unit on this machine for that purpose.
Chapter 3
To ensure a high flow air supply, ½” tubing is used to supply air to the valve manifolds. Plastic silencers on both ends of the manifold Understanding
reduce noise and ensure minimal restriction of exhaust air. Pneumatic Air
Preparation
Chapter 4
The valves were wired using solenoid cables which include built-in surge suppression and an LED to show when power is present to the Pneumatic Actuator
solenoid. Surge suppression improves the life of the PLC outputs by eliminating voltage spikes, and the LED indicator clearly shows valve
status which simplifies and speeds maintenance. Chapter 5
Valves for
Pneumatic
Cylinders
Pneumatic Cylinder Details Chapter 6
Pneumatic
The pneumatic cylinder configurations were specified based Tubing &
Hose
on space constraints and required motion. In places where the
Chapter 7
cylinder is producing rotational motion, either by moving a Are Pneumatic
Pneumatic
Components
Fittings
lever or pushing a rack turning a gear, the machine uses tie rod Compatible?
cylinders with built-in cushions. For other low power or Chapter 8
Electro
Are Pneumatic
Pneumatic
supplemental motion, the machine uses either round-body Systems in Action
Components
Compatibl9
(Figure 13D) or compact cylinders.
Chapter 9
Pneumatic
Electro Pneumatic
Pneumatic cylinders provide all the motion required to feed, System Design
Systems in Acti
Considerations
assemble and stack the trays (except for the vertical tray blank Chapter 10
feed wheel motion, which is electromechanical). All cylinders Pneumatic
System Design
critical to the assembly/setup of the tray include magnet Considerations
Chapter 11
resistance sensors along with magnetic pistons in the Pneumatic
Energy Actuator
Efficient
cylinders. The sensors provide error-proofing of cylinder Figure 13D: Compact cylinders. These Compact cylinders were selected for Pneumatic Systems
their small size, and are some of the many pneumatic cylinders controlling
end-of-stroke motion for each step of the machine assembly mechanical motion in the traymaker Chapter 12
sequence. Pneumatic Actuator
The Nitra® pneumatics from AutomationDirect work as well as their more expensive competition, and RMD has used them in lubricated Chapter 13
Application
and non-lubed applications with great success. Stories
Chapter 13
57
pneumatics
Application Stories
Supplier Selection
RMD chose AutomationDirect as a primary supplier of the traymaker automation, power, pneumatic and other components. They were
Chapter
13
selected for the affordability and quick availability of the wide variety of products required for this application. AutomationDirect’s
technical documentation is available 24/7 on their website, and phone support is available without a support contract. Other factors leading
to their supplier selection included the free customer support forum, free 2-day shipping and free programming software.
The traymaker is controlled by an AutomationDirect CLICK C0-00DR-D PLC with expansion I/O and terminal blocks for field
wiring. A bulkhead programming port with outlet on the control enclosure door simplifies compliance with arc flash regulations as it
allows changes to be made to the controller software without opening the door (Figure 13E).
AutomationDirect also provided the power distribution hardware including a non-fused disconnect switch, branch circuit protection
circuit breakers, and a rotary motor protector switch to disconnect power from the motor drive.
Jump to
Operator control buttons include a selector switch, pushbuttons and an E-stop mushroom pushbutton. To sense the product, background Chapter
Chapter 1
suppression photoeyes and cylinder position sensors were used. Why Use
Pneumatics?
The end result shows that, with strong customer buy-in, you can build a reliable machine using the affordable products provided Chapter 2
by AutomationDirect. Other factors valued by this and other customers include simple operation, low maintenance and industry-leading Pneumatic Circuit
Symbols Explained
customer support.
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Are Pneumatic
Pneumatic
Components
Fittings
Compatible?
Figure 13E: Control enclosure. Like the rest of Chapter 8
Electro
Are Pneumatic
Pneumatic
the machine, the control panel is fully portable Systems in Action
Components
Compatibl9
Chapter 9
Pneumatic
Electro Pneumatic
System Design
Systems in Acti
Considerations
Chapter 10
Pneumatic
System Design
Considerations
Chapter 11
Pneumatic
Energy Actuator
Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Chapter 13
58
pneumatics
Application Stories
Riada Equipment Solves Difficult

Packaging Problem
Riada Equipment is based out of Winder, GA and has been solving problems for cleaning product, food & beverage, textile, cosmetic,
lubricant, and glue & adhesive customers since 1984. The company offers new bottling equipment, and also re-manufactures existing cus-
Chapter
13
tomer equipment.
Handling and filling oval shampoo bottles required innovative design of custom machinery.
When asked where the exotic company name came from, owner Ross Adair said it was
just his last name turned backward. How clever. When a long-time customer ran across a
difficult bottling application, they turned to Riada to solve it, calling on that very cleverness.
The difficulty in this particular customer’s case centered on uniquely-shaped shampoo

bottles. The oval containers precluded stacking, and also conveying bottle-to-bottle.
Instead, each bottle had to be indexed and then clamped individually for the filling
Jump to
sequence. To accomplish this, Riada decided to use a programmable logic controller and Chapter
associated system components from AutomationDirect. Chapter 1
Why Use
Pneumatics?
Controlling Machine Motion Chapter 2

Pneumatic Circuit
The machine entry section consists of a set of DC motor-controlled round spacing wheels that move the bottles onto the machine belt Symbols Explained
conveyor for filling. Running at a speed slightly less than the belt conveyor, the feed wheels space the bottles at the correct distance for
Chapter 3
the fill nozzles and bottle clamps. The belt conveyor speed is regulated by an AutomationDirect GS-2 series AC drive. Understanding
Pneumatic Air
Preparation
Round-body style entry and exit pneumatic gate cylinders are also supplied by AutomationDirect, and they control the overall 10-bottle Chapter 4
group container flow into the machine, and out of the machine to downstream operations. Pneumatic Actuator
As the bottles enter the machine, they are counted by an Automation- Chapter 5
Valves for
Direct MVP series retro-reflective photo eye. If the machine is set up for a Pneumatic
Cylinders
ten-bottle run, then ten bottles are counted on the way in or the cycle
Chapter 6
is halted. The bottle count is decremented as bottles exit the machine, and Pneumatic
Tubing &
the machine cycle is halted if the total count doesn’t reach zero. Hose
Chapter 7
Are Pneumatic
Pneumatic
A set of AutomationDirect NITRA brand E-Series rod-guided pneumatic Components
Fittings
Compatible?
cylinders is located at each of the ten fill stations and is used to clamp and
Chapter 8
hold the bottles. This dual-rod design translates the force of the air into Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
precise linear motion and minimizes any side-to-side movement. This is Compatibl9
critical to the clamping sequence as it minimizes clamp-settling time. Chapter 9
Pneumatic
Electro Pneumatic
System Design
Systems in Acti
An AutomationDirect MV2-series photo-eye at each station individually detects the presence of a bottle and controls the clamping Considerations
Chapter 10
sequence. Since space in the dispensing area is at a premium, the MV2 diffuse type photo eye was used at each station to sense the Pneumatic
presence of a bottle. This type of sensor eliminates the need to mount either a reflector or receiver on the other side of the sensing line. System Design
Considerations
Chapter 11
AutomationDirect NITRA brand pneumatic equipment is prevalent throughout the machine. An AFR series filter-regulator provides the Pneumatic
Energy Actuator
Efficient
Pneumatic Systems
machine with clean air at the right pressure, and Riada added a 3rd party receiver tank to provide excess capacity and minimize any drops
in air pressure regardless of the real-time air load, ensuring consistent cycle times. Chapter 12
Pneumatic Actuator
Manifold-mounted AutomationDirect AVS-5 series 5-port 4-way solenoid valves provide the air control function required by the
double-acting pneumatic cylinders. MLA series air header manifolds were added at the machine front and rear to distribute air with Chapter 13
Application
minimum piping runs, with the result being higher air pressure and more consistent cycle times. Stories
Chapter 13
59
pneumatics
Application Stories
Dispensing Operations
Chapter
Filling the customer’s containers with product is the primary job of the machine. All equipment with surfaces touching the product meets
13
FDA specification, including the stainless steel metering cylinders, and the shut-off stopper cylinders at each nozzle.
Supplying the force to move those cylinders are AutomationDirect D-series NFPA tie rod
cylinders. At the rear face of each tie rod cylinder are threaded rods and handles. Each
rod travels through customer-supplied holes, and penetrates the rear face of the tie rod
cylinder to provide a stop for its piston.
Manually adjusting the rod length varies the stroke of the tie rod cylinder, which in turn
varies the volume dispensed by the stainless cylinder, a very simple yet effective design.
Different color pressure and exhaust tubing separates the lines to facilitate tracing for
Jump to
troubleshooting. Chapter
Chapter 1
Why Use
Control and Operator Interface Pneumatics?
The entire machine sequence is controlled by an AutomationDirect DirectLogic DL-06 programmable logic controller. This brick style Chapter 2
Pneumatic Circuit
unit contains both the CPU and sufficient I/O to meet the machine requirements. An AutomationDirect six-inch EA9 series color Symbols Explained
touch-screen C-More human-machine interface (HMI) allows for flexible machine product and cycle time setup. The HMI is used to
Chapter 3
set up various timers and variables for the filling process. It’s also used to control machine start and stop, minimizing the need Understanding
Pneumatic Air
for pushbuttons. Preparation
Chapter 4
Besides operating screens, a maintenance screen is included. This screen allows operators to run the machine dry for testing various Pneumatic Actuator
components and operations. Typical dry runs include clamping and unclamping of bottles, raising and lowering fill heads, and running
Chapter 5
the machine through its entire sequence without dispensing any product. Valves for
Pneumatic
Cylinders
Test and Results Chapter 6
Pneumatic
Shop test was performed at the Riada facility in Tubing &
Hose
Winder, Georgia. Minor PLC program changes Chapter 7
during shop test were done remotely by Riada’s Are Pneumatic
Pneumatic
Components
Fittings
systems integrator, Systems & Controls of Lenoir City, Compatible?
Chapter 8
TN. The integrator’s PC was connected remotely to Electro
Are Pneumatic
Pneumatic
Riada’s shop floor PC running DirectLogic programming Systems in Action
Components
Compatibl9
software. The connection was made over a wireless Chapter 9
Pneumatic
plant network at the Winder location. Successful shop Electro Pneumatic
System Design
Systems in Acti
Considerations
test and product run-off with the customer allowed
Chapter 10
Riada to receive final sign-off prior to shipment, a Pneumatic
System Design
critical milestone. Considerations
Chapter 11
The machine has been running for two shifts a day Pneumatic
Energy Actuator
Efficient
Pneumatic Systems
since November 2014 without interruption. Due to
these uccessful results, the customer ordered and Riada Chapter 12
Pneumatic Actuator
delivered clamping systems for two of the customer’s vs. Electromechanical
existing machines.
Chapter 13
Application
Stories
Chapter 13
60
pneumatics
Application Stories
DIY Pneumatic Saw Clamp

Many years ago my father was working on a new shop behind his house. The
insides were left for us to finish. We needed to build work benches, shelves and
Chapter
13
racks. To save money, he bought the longer 2x4 sized lumber and we’d cut it to
whatever size was needed. This worked out great but the extra-long boards were un-
ruly and a challenge to cut by one person because of the length. We didn’t have a nice
chop saw setup that is so common now with the nice outriggers and side supports.
We basically made a saw with an old Black and Decker work bench. The kind with
the clamp built into the table top.
After many cuts using one hand on the saw and one hand trying to balance the
board, I knew there had to be a better way. I started using the manual clamp that
came with the saw but its range was pretty limited and it was better suited for
thinner material than a 2x4. I remembered a pneumatic cylinder that I had grabbed Jump to
Chapter
out of a junk pile and thought that I might be able to make an automatic clamp with it. Chapter 1
I found a piece of steel to mount the pneumatic cylinder to and then used a section of Why Use
Pneumatics?
rod for the post. The rod had to be turned down by a friend on a lathe so it would fit in the clamp mount on the saw.
Chapter 2
Pneumatic Circuit
When I first used the pneumatic clamp on the saw I was amazed at how much force it had. I was able to place a 14 foot board under it Symbols Explained
and it would lift it and keep it perfectly clamped on the saw. When you’re trying to cut off 2 feet of a 14 foot board, that’s a big deal.
Chapter 3
Understanding
It was so useful for my dad and me that I wanted to revisit the project and share it on my website Neo7CNC.com and the Neo7CNC Pneumatic Air
Preparation
YouTube channel. I started documenting my very first DIY CNC machine build years ago and posted the videos on YouTube. With each Chapter 4
new CNC machine or contraption I built, interest on the channel kept growing. I’ve continued to share my machines, experiences and Pneumatic Actuator
information ever since. I really enjoy inspiring others to make things (CNC or not) and the interaction with viewers and sharing of
knowledge is a huge bonus. Since randomly finding a pneumatic cylinder doesn’t translate very well to my viewers, I wanted to find a Chapter 5
Valves for
source for most, if not all of the needed components for this build. Pneumatic
Cylinders
Chapter 6
AutomationDirect.com was my first choice. With a great selection, good prices and fast shipping, it was a no brainer. I’ve used them Pneumatic
Tubing &
many times over the years. Not just for pneumatic parts but also for buttons, enclosures, sensors and much more. I was able to find Hose
just about everything from them. The only other items needed can be found at most local hardware stores. Chapter 7
Are Pneumatic
Pneumatic
Components
Fittings
To see how pneumatics was used in the saw clamp application or if you’re interested in DIY projects and CNC machines, please stop by the Compatible?
Neo7CNC.com website and YouTube channel. Chapter 8
Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
Compatibl9
Chapter 9
Pneumatic
Electro Pneumatic
System Design
Systems in Acti
Considerations
Chapter 10
Pneumatic
System Design
Considerations
Chapter 11
Pneumatic
Energy Actuator
Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Chapter 13
61
pneumatics
Application Stories
DIY Halloween
Chapter
When you think of Halloween you probably have in mind something creepy, scary, or horrifyingly
haunting to use as your Halloween props. But how do you give it that something special, that
13
“scream factor”? That’s where AutomationDirect comes in…
Thanks to products from AutomationDirect you can create

something to scare trick-or-treaters.
Check out our video series on automating Halloween
props. This series has been quite a hit with viewers and
we’ve kicked things up a notch or two with a classic horror
movie-style piece. Hopefully our recent DIY Halloween
Prop video will scare…I mean…inspire you.
Jump to
Each video on this page explains how to build a DIY Chapter
Halloween pneumatic creation step-by-step. The best Chapter 1
Why Use
part about using a pneumatic component is its ability Pneumatics?
to automate endless types of props from a bone shaking Chapter 2

skeleton, to a crazed zombie or even open and close doors Pneumatic Circuit
Symbols Explained
and few dresser drawers. Happy haunting!
Chapter 3
Understanding
Pneumatic Air
Preparation
Chapter 4
Pneumatic Actuator
Chapter 5
Valves for
Pneumatic
Cylinders
Chapter 6
Pneumatic
Tubing &
Hose
Chapter 7
Are Pneumatic
Pneumatic
Components
Fittings
Compatible?
Chapter 8
Electro
Are Pneumatic
Pneumatic
Systems in Action
Components
Compatibl9
Chapter 9
Pneumatic
Electro Pneumatic
System Design
Systems in Acti
Considerations
Chapter 10
Pneumatic
System Design
Considerations
Chapter 11
Pneumatic
Energy Actuator
Efficient
Pneumatic Systems
Chapter 12
Pneumatic Actuator
Chapter 13
Application
Stories
Chapter 13
62

Pneumatics Practical Guide

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Pneumatics Practical Guide

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pneumatics

Thread Standards Chapter 5

if not provided with sealant from the factory.

Tapered Thread Straight Thread

Seal is accomplished Chapter 3

Figure 7D:Quick-exhaust valve

Check Valves and Stop Valves

Here are examples of a few components that have interchangeable sources:

Non-Repairable Air Cylinders

2-way diaphragm Chapter 10

2-way stackable Chapter 12

Table 8B: Pipeline Valves Chapter 13

Compact Air Cylinders

Double Acting 100mm 100mm GND- MACQ- UND- CDQ2A-

Table 8C: Examples of Compact Extruded Body Cylinder

Who’s the Boss?

Figure 9B: Pneumatic diverter belt, up position

Figure 9F: Pressure sensor example

is in its lowered position. Chapter 6

Compressed Air Supply

Figure 10C: Interactive Cylinder Bore Calculator

Valve Actuation Chapter 2

Minimize Leaks Chapter 5

Regulate the Return Stroke

cylinders more than necessary. Some oversizing is necessary Chapter 8

Save Energy, Save Money Chapter 6

Picking the Right Pick-and-Place

When Pneumatics are Better Chapter 3

• More compact in most cases

Table 12A: Advantages of Pneumatic Pick-and-Place Systems Chapter 10

Stroke Length Considerations

Speed Control Concerns

Grippers and Vacuum Device Deployment Chapter 2

Reducing Total Cost of Ownership

The Choice is Yours

Difficult Packaging Problem

DIY Halloween Pneumatic Systems

Pneumatics Improve Ridgeline Machine’s Equipment

The Model 25 automatic traymaker was developed in partnership Chapter 13

Pneumatic Assembly of Trays

The traymaker pneumatic components start with a 3/8-inch

Riada Equipment Solves Difficult

The difficulty in this particular customer’s case centered on uniquely-shaped shampoo

Controlling Machine Motion Chapter 2

DIY Pneumatic Saw Clamp

“scream factor”? That’s where AutomationDirect comes in…

Thanks to products from AutomationDirect you can create

to automate endless types of props from a bone shaking Chapter 2

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