1. PNEUMATICS

2. USE OF PNEUMATICS THE ADVANTAGES

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

4. 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

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

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

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

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

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

10. PNEUMATICS HOW IT WORKS

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

12. 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

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

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

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

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

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

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

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

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

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

22. COMPRESSOR COMPRESSOR THOMAS INDUSTRIES  ELECTRICALLY DRIVEN

23. COMPRESSOR COMPRESSOR THOMAS INDUSTRIES ADDITIONAL COMPONENTS RELIEF VALVE ON COMPRESSOR

24. COMPRESSOR COMPRESSOR THOMAS INDUSTRIES ADDITIONAL COMPONENTS GAUGE

25. COMPRESSOR COMPRESSOR THOMAS INDUSTRIES ADDITIONAL COMPONENTS PRESSURE SWITCH

26. COMPRESSOR COMPRESSOR THOMAS INDUSTRIES ADDITIONAL COMPONENTS Plug Valve

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

28. 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

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

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

31. 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

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

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

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

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

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

37. 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

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

39. FITTINGS CONNECTION AND DISCONNECTION

40. FACTS ABOUT PNEUMATICS

41. 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

42. 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 01234 Bars Absolute 12345 PSIG Gauge 014. 7 29. 4 43. 5 58. 8 PSIA Absolute 14. 7 29. 4 44. 1 58. 8 73. 5

43. 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 01234 Bars Absolute 12345 PSIG Gauge 014.729.443.558.8 PSIA Absolute 14.729.444.158.873.5 ~164.1 psig at sea level

44. FORCE PRINCIPLES

45. 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

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

47. TRANSMISSION PRINCIPLES

49. VALVES ARE IN CONTROL

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

51. VALVES ARE IN CONTROL FLOW CONTROLS NEEDLE VALVES

52. 4-WAY VALVES CONTROL FLOW SOLENOID SPRING

53. 4-WAY VALVES DOUBLE SOLENOID (DETENTED)

54. 4-WAY VALVES Single Solenoid (spring offset)

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

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

57. 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.

58. ACTUATORS MAKE THINGS MOVE

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

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

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

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

63. ACTUATORS CONSTRUCTION & OPERATION BASIC CONSTRUCTION

64. ACTUATORS CONSTRUCTION & OPERATION OPERATION

65. 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

66. 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.

67. 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

68. 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

69. 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

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

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

72. ACTUATORS ANGLES Power Factor Angle AFactor 10.174 20.342 45.707 50.766 60.867 75.966 901.0 FORCE T = (CYLINDER FORCE)(SIN A )

73. 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

74. Actuators Angles HOW MUCH FORCE MUST THE CYLINDER DEVELOP?

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

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

77. ACTUATORS - ANGLES SOLUTION: STEP 2 – EFFECTIVE CYLINDER FORCE AT RIGHT ANGLES TO SUPPORT WEIGHT = (9.65)ARM RATIO (17/5) = 32.79 LBS = F1

78. ACTUATORS - ANGLES SOLUTION : STEP 3 – ACTUAL CYLINDER FORCE ACTING AT 30 = F1 / SIN 30 = 65.59 LBS = F

79. 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

80. 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

81. 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.

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

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

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

85. 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

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

87. 1.5” BORE CYLINDER

89. RETRACTED LENGTH = 4.38 + STROKE +.25 + 1.31 = 5.94 + STROKE BASE DIMENSION = 4.38 + STROKE LENGTH = ? + LOCKING NUT =.25 + CLEVIS DIMENSION = 1.31 EXTENDED LENGTH = 5.94 + (2 X STROKE LENGTH)