Basic Pneumatic - Introduction

Basic Pneumatic – Introduction
Solenoid Valve
Directional Control Valves are just as their name implies. They control the direction that
the air goes by channeling it to different ports. They are often used to control air
cylinders. Like cylinders they come in a variety of sizes and shapes. The valves have
specific applications depending on their design.
Flow Control Valve
Flow Control Valves are used to control the speed at which an air cylinder moves when
air is applied to it.
The valve can be adjusted by turning a knob. It controls the air in one direction and
allows it to flow with no restriction the other or opposite direction. Proper adjustment of
these controls will extend the life of the cylinder by controlling its speed.
Air Cylinders
Air Cylinders are the part of a pneumatic system that performs a task, such as moving a
part of a machine, lifts or lowers, or even as little as applying pressure to hold
something in place.
Basic Pneumatic – Valves

There are many types of valves in a compressed air system. Each has its own special
purpose:
Ball valves are usually for on/off applications.
Flow Control Valves are for controlling the flow of air. And the speed of the cylinder or
device it is attached to.
Dump valves are shut off valves that also bleed off any residual air pressure these are
used for safety shut off valves.
Exhaust Mufflers are for the purpose of noise reduction.

Basic Pneumatic – Solenoid
Solenoid valves are commonly used in the plant and use an electromagnet to move the
internal piston from one position to another which in turns causes the air cylinder to
move in different directions. In a single solenoid valve the piston moves in one direction
when power is applied to the solenoid and in the other direction by an internal spring.
Double solenoid valves move the piston in the direction that power is being applied the
solenoid. It will remain in this position until the other solenoid is activated.
Single solenoid 2 position valve
Double solenoid 2 position valve
Basic Pneumatic – Cylinders

Air Cylinders:
Air Cylinders are the part of a pneumatic system that performs a task, such as moving a
part of a machine, lifts or lowers, or even as little as applying pressure to hold
something in place.
Single acting cylinder

Double acting cylinder
Basic Components of a Pneumatic Valves:

Valves control the switching and routing of air in a pneumatic system. Valves not only
have to control the flow of the compressed air, they also have to control the flow of the
exhaust to the atmosphere. There are two main types of valves used in pneumatic
switching circuits: 2/3 valve and 2/5 valves.
Air Cylinders:
They come in a variety
Of sizes and shapes and are made by

Numerous companies. It is important to
Understand the basic principle of an
air cylinder.
Basic Components of a Pneumatic Cylinder:

Cylinders convert the energy in the compressed air into straight motion (forward and
backward or up and down). The air enters the cylinder and pushes a piston from one
end of the cylinder to the other.
Basic Components of a Pneumatic Cylinder:
Single Acting Cylinders:
A single acting cylinder has only one air connection, while a double acting has two.
With a single acting cylinder, the piston is pushed outwards by the pressure of the
air. When the air supply is removed and the air inside the cylinder is allowed to escape
(we call this the exhaust), the piston moves back to its rest position using a compressed
spring.
Double Acting Cylinders:
The double acting cylinder has two air connections. When compressed air is sent to
one side and the other side is allowed to exhaust, the piston is pushed to one end of the
cylinder. When air is then sent to the other side and the first side is allowed to exhaust,
the piston is pushed back. This type of cylinder is more powerful on the return stroke
than the single acting cylinder.
Basic Pneumatic – Safety
System Hazards:
The pneumatic system can pose two potential safety hazards:
* Pinch Points
* Stored Energy
Both can potentially cause bodily and equipment harm. The Pneumatic system is
composed of both moving and non-moving components. Particularly, where there are
air cylinders (moving parts). Pinch points are one of the primary safety concerns. For
example: If your hand or any other part of your body gets caught between the shaft of
an air cylinder and another piece of equipment, injury could result. Therefore, the
importance of following LOTO procedures is essential!
In regards to non-moving components of the pneumatic system, stored energy becomes

a primary concern. When air is under pressure, there is the possibility of the air being
released unexpectedly potentially causing bodily harm or damage to equipment. For
example: stored energy can also cause the cylinder to move in the opposite direction
once air pressure is released.
Air Leaks:
If the system experiences a sudden loss of pressure or there is a hissing noise, there is
a leak somewhere in the system. The leak could indicate a fractured pipe or broken
hose. If the pipe/hose ruptures or blows apart, personnel and equipment could be in
danger.
Never attempt to find a leak by running a hand over the piping without the proper PPE.
Due to high pressure, the compressed air could enter the hand through the skin causing
a serious injury.
Never tighten airline fittings while they are under pressure. Isolate the air line and bleed
off the air pressure, before making any repairs.
Swollen areas on air lines are an indication of wear and could burst. They must be
repaired or replaced immediately.
As compressed air is produced, oil and moisture are mixed with the air. When the
compressed air leaves the compressor, the oil and water mixture may be in the form of
a fine mist. The oil contained in the mist is flammable. A spark or open flame can ignite
the air and oil moisture. In the event of a leak in the system near the compressor, keep
all open flames and sparks away. There are separators and a dryer to remove the oil
and moisture from the air before it leaves the mechanical room.
There is always electrical wiring around the components of a pneumatic

system. Ensure that any loose or bare wiring is F – Tagged immediately .
Broken or Damaged wiring could create a spark that could ignite the oil and air mixture.
Basic Pneumatic – Vibrators

Pneumatic vibrators use compressed air to force a metal ball to spin in a circle at very
high speeds. This creates vibration, which can help components feed down the line in
certain applications.
Inspection: To avoid waste, set the air flow at the lowest rate that still does the job.
Vacuum System
Vacuum Systems have many uses, to open shippers in the cases packers, pull down
cartons and transfer pouches from the gripper chain etc.
Here are some examples of some vacuum pumps that are used in food manufacturing
factory.
Some Vacuum Systems used in the factory are what is known as Vacuum Generators
or Venturi Systems.
The Vacuum System consist of an air source or air supply, a filter to clean the air going
into the system, a pressure control valve or regulator to control the amount of air
pressure, piping and fittings, direction control valve or solenoid valve which allows air to
travel through the vacuum valve, and the vacuum valve. There is no oiler in this type of
system. There is an added filter in this system in the vacuum or suction line. Trash
particles and debris must be kept out of the vacuum generator. At the end of the line is
the Vacuum Cups (Suction Cups). The Vacuum Cups are what does the work. They
come in all different sizes and shapes and are made from many types of materials.
Vacuum Generators generally operate off of low air pressure which is used to produce
the vacuum. The size and type of generator will determine how much air is needed and
the amount of hold it has. The air comes into one side of the valve and exits out the
other side. In the middle is where the vacuum is generated. This is produced by air
passing through chambers within the valve. This type of vacuum generator is expensive
to operate because of the compressed air used. Vacuum pumps are a lower cost
method of generating vacuum.
Vacuum Filters
Care and Maintenance

Just like the Pneumatic System, it’s important to make sure there are no leaks in a
Vacuum System. It is necessary to check lines for hole make sure the vacuum cups
don’t have holes in them and are not torn or worn which can result in vacuum loss. The
filters need to be kept clean so the vacuum or suction is not reduced. That’s why the
pick off filters and Brenton are so important to ensure reliability

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Basic Pneumatic – Introduction

Basic Pneumatic – Valves

Ball valves are usually for on/off applications.

Exhaust Mufflers are for the purpose of noise reduction.

Single solenoid 2 position valve

Double solenoid 2 position valve

Basic Pneumatic – Cylinders

Single acting cylinder

Basic Components of a Pneumatic Valves:

They come in a variety

Of sizes and shapes and are made by

Understand the basic principle of an

Basic Components of a Pneumatic Cylinder:

Double Acting Cylinders:

In regards to non-moving components of the pneumatic system, stored energy becomes

There is always electrical wiring around the components of a pneumatic

Basic Pneumatic – Vibrators

Care and Maintenance

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