PNEUMATICS

USE OF PNEUMATICS THE ADVANTAGES

PNEUMATICS THE ADVANTAGES WEIGHT EQUAL OR LIGHTER THAN COMPARABLE ALTERNATIVES SIMPLE REVIEW THE MANUAL AND YOU’RE READY TO GO

PNEUMATICS THE ADVANTAGES ADJUSTABLE FORCE BY ADJUSTING THE APPLIED PRESSURE YOU CAN INSTANTLY ADJUST THE FORCE DURABLE NO BURNED UP MOTORS – STALL WITH NO DAMAGE

PNEUMATICS THE ADVANTAGES STRONG FROM 9 LBS TO 180 LBS – EASILY ADJUSTABLE COMPLETE ALL NECESSARY PARTS INCLUDED

PNEUMATICS THE ADVANTAGES CUSTOM CYLINDERS - DIFFERENT ACTUATORS AVAILABLE LAST MINUTE ADDITIONS ADD A VALVE OR A CYLINDER QUICKLY

POWER TRANSMISSION & CONTROL THREE METHODS  ELECTRICAL  MECHANICAL  FLUID POWER

POWER TRANSMISSION & CONTROL FLUID POWER HYDRAULICS OIL, WATER, OTHER LIQUIDS PNEUMATICS AIR, OTHER GASES

POWER TRANSMISSION & CONTROL FLUID POWER – REMEMBER: LIQUID OR GAS HYDRAULICS OIL, WATER, OTHER LIQUIDS PNEUMATICS AIR, OTHER GASES

PNEUMATICS HOW IT WORKS

PNEUMATICS COMPRESSOR (& ADD’L COMPONENTS) CONNECTORS VALVES ACTUATORS (CYLINDERS)

PNEUMATICS – HOW IT WORKS. COMPRESSOR CONVERTS ELECTRICAL ENERGY TO PNEUMATIC ENERGY – PRESSURIZED AIR HAS POTENTIAL ENERGY ANALOGOUS TO A GENERATOR – CONVERTS FUEL ENERGY TO ELECTRICAL ENERGY – VOLTAGE HAS POTENTIAL ENERGY

PNEUMATICS – HOW IT WORKS. CONNECTORS TUBING AND FITTINGS – ANALOGOUS TO WIRES AND TERMINALS

PNEUMATICS – HOW IT WORKS. VALVES DIRECTIONAL CONTROL – CONTROLS THE FLOW TO THE ACTUATOR - ANALOGOUS TO RELAYS OR CONTROLLERS

PNEUMATICS – HOW IT WORKS. VALVES FLOW CONTROL – CONTROLS THE RATE OR THE DIRECTION OF FLOW – ANALOGOUS TO RESISTORS OR DIODES

PNEUMATICS – HOW IT WORKS. VALVES PRESSURE CONTROL – CONTROLS THE LEVEL OF POTENTIAL ENERGY – ANALOGOUS TO TRANSFORMERS

Pneumatics – How it Works. ACTUATORS TRANSFORM POTENTIAL ENERGY TO WORK LINEAR – OFTEN CALLED CYLINDERS – STRAIGHT LINE BUT CAN BE CONFIGURED TO PERFORM COMPLEX MOTION

Pneumatics – How it Works. ACTUATORS TRANSFORM POTENTIAL ENERGY TO WORK ROTARY LIMITED ROTATION E.G. RACK & PINION

Pneumatics – How it Works. ACTUATORS TRANSFORM POTENTIAL ENERGY TO WORK ROTARY CONTINUOUS ROTATION E.G. AIR MOTORS OR TURBINES

Pneumatics – How it Works. ACTUATORS TRANSFORM POTENTIAL ENERGY TO WORK CLAMPS

PNEUMATICS THIS IS WHAT YOU’LL USE TO MOVE THAT ROBOT

COMPRESSOR COMPRESSOR THOMAS INDUSTRIES  ELECTRICALLY DRIVEN

COMPRESSOR COMPRESSOR THOMAS INDUSTRIES ADDITIONAL COMPONENTS RELIEF VALVE ON COMPRESSOR

COMPRESSOR COMPRESSOR THOMAS INDUSTRIES ADDITIONAL COMPONENTS GAUGE

COMPRESSOR COMPRESSOR THOMAS INDUSTRIES ADDITIONAL COMPONENTS PRESSURE SWITCH

COMPRESSOR COMPRESSOR THOMAS INDUSTRIES ADDITIONAL COMPONENTS Plug Valve

COMPRESSOR COMPRESSOR THOMAS INDUSTRIES ADDITIONAL COMPONENTS Tank(2pcs.)

COMPRESSOR  ELECTRICALLY DRIVEN  ADDITIONAL COMPONENTS CHECK VALVE FLOW IN ONE DIRECTION COMPRESSOR AND RELIEF VALVE TANKS AND PRESSURE SWITCH GAUGE AND PLUG VALVE REGULATORS WITH GAUGES

THE COMPRESSOR SYSTEM ADDITIONAL COMPONENTS TANKS & GAUGE PRESSURE SWITCH RELIEF VALVE PLUG VALVE Pressure NCNO

AIR SUPPLY AMBIENT AIR IS COMPRESSED - IN INDUSTRIAL APPLICATIONS THE AIR IS ‘PREPARED’ AIR PREPARATION – FRL – FILTER - REGULATOR – LUBRICATOR HERE’S WHY ….

AIR SUPPLY AMBIENT AIR IS COMPRESSED AIR PREPARATION – FRL – FILTER - REGULATOR - LUBRICATOR BUT DUST, DIRT AND WATER ARE INCLUDED IN INDUSTRIAL APPLICATIONS, CONTAMINANTS ARE REMOVED THROUGH THE USE OF FILTERS

AIR SUPPLY - FILTERS MESH SCREENS OR SINTERED METAL BAFFLES REMOVE DIRT SPINNING ACTION FORCES WATER AND CONTAMINANTS OUT OF THE AIR STREAM

AIR SUPPLY - FILTERS SPECIAL FILTER MATERIALS REMOVE OTHER ENTRAINED CONTAMINANTS LIKE OIL VAPORS MORE WATER CAN BE REMOVED BY AIR DRYERS CHEMICAL MECHANICAL

AIR SUPPLY - REGULATOR REGULATORS CONTROL PRESSURE RELIEVING TYPE IN THE FIRST KIT NON-RELIEVING TYPE CAN TRAP PRESSURE

AIR SUPPLY - REGULATOR THE USE OF REGULATORS ASSURES MAXIMUM EFFICIENCY SET REGULATORS TO ABOUT TWICE MINIMUM PRESSURE NECESSARY TO OPERATE THE CYLINDER UNDER LOAD

About Pressure SAFETY MUST ALWAYS BE CONSIDERED. COMPRESSED AIR IS LIKE A COILED SPRING THAT CAN BE ROUTED TO WHERE IT IS NEEDED

PRESSURE INFO THE BORE, STROKE AND MOTOR HORSEPOWER WILL BE AVAILABLE CONTROL THE PRESSURE FROM THE COMPRESSOR THE RATIO OF THE UNCOMPRESSED VOLUME TO THE COMPRESSED VOLUME IS THE COMPRESSION RATIO RELIEF VALVE AND REGULATOR CONTROL THE WORKING PRESSURE COMPRESSED AIR IS STORED IN THE TANKS AS A RESERVE. THE HIGHER THE STORAGE PRESSURE AND THE GREATER THE VOLUME, THE MORE USABLE ENERGY

CONNECTORS HUNDREDS OF VARIATIONS AVAILABLE SIZE, TYPE OF CONNECTION, NUMBER OF PORTS TUBING OR PIPE TAPERED PIPE THREAD GENERALLY BRASS USE TEFLON TAPE CORRECTLY

FITTINGS CONNECTION AND DISCONNECTION

FACTS ABOUT PNEUMATICS

FACTS ABOUT PNEUMATICS PRESSURE – POTENTIAL ENERGY LBS PER IN 2 OR FORCE PER UNIT AREA ABSOLUTE PRESSURE – 14.7 psia AT SEA LEVEL GAUGE PRESSURE – MEASURED RELATIVE TO AMBIENT FLOW CFM OR VOLUME PER UNIT TIME SCFM

FACTS ABOUT PNEUMATICS UNIVERSAL GAS LAWS – BOYLE’S LAW IF TEMPERATURE REMAINS CONSTANT P 1 X V 1 = P 2 X V 2 IF TEMPERATURE REMAINS CONSTANT ABSOLUTE PRESSURE THAT MEANS IF YOU CUT THE VOLUME IN HALF THE ABSOLUTE PRESSURE DOUBLES – THAT’S HOW THE COMPRESSOR WORKS Relationship between Bars, Gauge and Absolute Pressure Bars Gauge Bars Absolute PSIG Gauge PSIA Absolute

FACTS ABOUT PNEUMATICS UNIVERSAL GAS LAWS – BOYLE’S LAW IF TEMPERATURE REMAINS CONSTANT P 1 X V 1 = P 2 X V 2 IF TEMPERATURE REMAINS CONSTANT ABSOLUTE PRESSURE THAT MEANS IF YOU CUT THE VOLUME IN HALF THE ABSOLUTE PRESSURE DOUBLES – THAT’S HOW THE COMPRESSOR WORKS Relationship between Bars, Gauge and Absolute Pressure Bars Gauge Bars Absolute PSIG Gauge PSIA Absolute ~164.1 psig at sea level

FORCE PRINCIPLES

GAUGE PRESSURE WORKS AGAINST EACH SQUARE INCH OF PISTON SURFACE THE GREATER THE SQUARE INCH SURFACE OF THE FLUID, THE LESS INTERNAL PRESSURE WILL BE DEVELOPED

FORCE PRINCIPLES UNIVERSAL GAS LAWS - PASCAL’S LAW PRESSURE ACTS AT RIGHT ANGLES TO THE CONFINING VESSEL – THAT’S HOW A CYLINDER WORKS

TRANSMISSION PRINCIPLES

VALVES ARE IN CONTROL

CONTROL PRESSURE RELIEF VALVES & REGULATORS CONTROL FLOW CHECK VALVES (USED ON COMPRESSOR)

VALVES ARE IN CONTROL FLOW CONTROLS NEEDLE VALVES

4-WAY VALVES CONTROL FLOW SOLENOID SPRING

4-WAY VALVES DOUBLE SOLENOID (DETENTED)

4-WAY VALVES Single Solenoid (spring offset)

VALVE SYMBOLS THE 4-WAY VALVES ARE ACTUALLY PILOT-OPERATED VALVES

VALVE SYMBOLS THE 4-WAY VALVES ARE ACTUALLY PILOT- OPERATED VALVES

VALVE SYMBOLS PILOT-OPERATORS ARE ACTUALLY 3-WAY NNP (NORMALLY NOT PASSING OR NORMALLY CLOSED) VALVES. THIS ALLOWS LOW-POWER SOLENOIDS TO USE THE AIR PRESSURE TO SWITCH THE MAIN SPOOL. SOLENOIDS THAT WOULD ACTUALLY MOVE THE MAIN SPOOL WOULD BE LARGE, HEAVY AND CONSUME A LOT OF POWER.

ACTUATORS MAKE THINGS MOVE

ACTUATORS MOST COMMON TYPES OF LINEAR ACTUATORS DOUBLE ACTING – SINGLE ENDED ALL CONTAIN CYLINDER BARREL PISTON ROD SEALS SPRING IF USED

ACTUATORS DOUBLE ACTING - DOUBLE ENDED ALL CONTAIN CYLINDER BARREL PISTON ROD SEALS SPRING IF USED

ACTUATORS MOST COMMON TYPES OF LINEAR ACTUATORS SINGLE ACTING - SINGLE ENDED ALL CONTAIN CYLINDER BARREL PISTON ROD SEALS SPRING IF USED

ACTUATORS SINGLE ENDED - SPRING RETURN All contain Cylinder Barrel Piston Rod Seals Spring if used

ACTUATORS CONSTRUCTION & OPERATION BASIC CONSTRUCTION

ACTUATORS CONSTRUCTION & OPERATION OPERATION

ACTUATORS - OPERATION WITH FLOW CONTROLS TYPICALLY FLOW CONTROLS ARE MOUNTED BETWEEN THE 4-WAY VALVE AND THE CYLINDER AS CLOSE TO THE CYLINDER AS PRACTICAL. THE INTERNAL CHECK VALVE PERMITS FREE FLOW TO THE CYLINDER FROM THE VALVE AND METERED FLOW FROM THE CYLINDER TO EXHAUST

ACTUATORS - OPERATION WITH FLOW CONTROLS Operation TYPICALLY FLOW CONTROLS ARE MOUNTED BETWEEN THE 4-WAY VALVE AND THE CYLINDER AS CLOSE TO THE CYLINDER AS PRACTICAL.

ACTUATORS DIFFERENTIAL AREAS FORCE CONSIDERATION CONSIDER THE EFFECTIVE AREA ON WHICH THE PRESSURE ACTS ON SINGLE ENDED CYLINDERS THERE IS A DIFFERENTIAL DON’T FORGET FRICTION

ACTUATORS - OPERATION WITH FLOW CONTROLS TYPICALLY FLOW CONTROLS ARE MOUNTED BETWEEN THE 4-WAY VALVE AND THE CYLINDER AS CLOSE TO THE CYLINDER AS PRACTICAL THE INTERNAL CHECK VALVE PERMITS FREE FLOW TO THE CYLINDER FROM THE VALVE AND METERED FLOW FROM THE CYLINDER TO EXHAUST

ACTUATORS - OPERATION WITH FLOW CONTROLS OPERATION TYPICALLY FLOW CONTROLS ARE MOUNTED BETWEEN THE 4-WAY VALVE AND THE CYLINDER AS CLOSE TO THE CYLINDER AS PRACTICAL THE INTERNAL CHECK VALVE PERMITS FREE FLOW TO THE CYLINDER FROM THE VALVE AND METERED FLOW FROM THE CYLINDER TO EXHAUST

APPLYING YOUR COMPONENTS FOR THE BEST RESULTS APPLY THE COMPONENTS CAREFULLY, FOLLOWING GOOD DESIGN PRACTICE AND THE FOLLOWING INFORMATION

ACTUATORS ANGLES FORCE T = (CYLINDER FORCE)(SIN A)

ACTUATORS ANGLES Power Factor Angle AFactor FORCE T = (CYLINDER FORCE)(SIN A )

ACTUATORS - ANGLES BE SURE TO CHECK ALL CYLINDER FOR FREEDOM OF MOVEMENT WITH PRESSURE OFF, MANUALLY MOVE THE CYLINDER AND MECHANICAL COMPONENTS THROUGH THE FULL STROKE OF THE CYLINDERS  Potential Interference Points

Actuators Angles HOW MUCH FORCE MUST THE CYLINDER DEVELOP?

ACTUATORS - ANGLES HOW MUCH FORCE MUST THE CYLINDER DEVELOP? LOAD 15 LBS - BOOM ANGLE 50

ACTUATORS - ANGLES SOLUTION: STEP 1 – FORCE AT RIGHT ANGLES TO SUPPORT WEIGHT = 15(.643) = 9.65 LBS = F2 (COS 50)=.643

ACTUATORS - ANGLES SOLUTION: STEP 2 – EFFECTIVE CYLINDER FORCE AT RIGHT ANGLES TO SUPPORT WEIGHT = (9.65)ARM RATIO (17/5) = LBS = F1

ACTUATORS - ANGLES SOLUTION : STEP 3 – ACTUAL CYLINDER FORCE ACTING AT 30 = F1 / SIN 30 = LBS = F

ACTUATOR(CYLINDER) DO’S AND DON’TS YOU DO NOT HAVE TO FULLY EXTEND A CYLINDER BUT YOU’LL NEED AN EXTERNAL STOP. AVOID SIDE-LOADING – INCREASES FRICTION AND WEAR Weight or force applied at 90° angle to the rod Wear, friction and leakage can occur at the rod seal and at the piston seal

ACTUATOR(CYLINDER) DO’S AND DON’TS AVOID GETTING GRIT OR METAL SHAVINGS ON THE ROD OR IN THE CYLINDER – CAUSES ABRASION AND SEAL DAMAGE USE FLOW CONTROLS FOR SAFETY

ACTUATOR(CYLINDER) DO’S AND DON’TS CYLINDER FORCE TO JUST BALANCE THE LOAD PUSH FORCE =  (CYLINDER RADIUS 2) PRESSURE (PSIG) PULL FORCE = PUSH FORCE -  (ROD RADIUS 2) PRESSURE (PSIG) USE ROUGHLY TWICE THE BALANCE FORCE FOR GOOD CONTROL.

ACTUATORS MOUNTING EXAMPLE: ARM TO BE RAISED BY CYLINDER DETERMINE OVERALL LENGTH OF RETRACTED CYLINDER DRAW AN ARC FROM THE MOUNTING POINT ON ARM

ACTUATORS MOUNTING EXAMPLE: ARM TO BE RAISED BY CYLINDER DETERMINE OVERALL LENGTH OF EXTENDED CYLINDER DRAW AN ARC FROM THE MOUNTING POINT ON ARM

ACTUATORS MOUNTING EXAMPLE: ARM TO BE RAISED BY CYLINDER WHERE ARCS INTERSECT IS THE MOUNTING POINT CHECK FOR INTERMEDIATE INTERFERENCE

CALCULATING CYLINDER DIMENSIONS BASED ON THE DRAWINGS IN THE PNEUMATIC MANUAL RETRACTED LENGTH FROM PIVOT PIN TO CLEVIS HOLE = BASE DIMENSION + STROKE LENGTH + LOCKING NUT + CLEVIS DIMENSION

CALCULATING CYLINDER DIMENSIONS BASED ON THE DRAWINGS IN THE PNEUMATIC MANUAL EXTENDED LENGTH FROM PIVOT PIN TO CLEVIS HOLE = RETRACTED LENGTH PLUS STROKE

1.5” BORE CYLINDER

RETRACTED LENGTH = STROKE = STROKE BASE DIMENSION = STROKE LENGTH = ? + LOCKING NUT =.25 + CLEVIS DIMENSION = 1.31 EXTENDED LENGTH = (2 X STROKE LENGTH)