UNIVERSITY OF SAN CARLOS

SCHOOL OF ENGINEERING

DEPARTMENT OF MECHANICAL AND MANUFACTURING ENGINEERING

Written Report on

Components and Assemblies in the Electrical Signal Control Section

In partial fulfillment for the requirements of

ME 2311 – Pneumatics

SUBMITTED BY:
Lico, Juhn Rherl
Bongo, Arki Ronan
Amaza, Regel Hans
Erasmo, John Michael Angelo

SUBMITTED TO:
Engr. Earl Ray Aniñon
3.1 Power supply unit

Power is supplied to the signal control section of an electro pneumatic controller via the
electrical mains. The said controller has a source for this purpose which is called the power
supply unit. The power supply unit or PSU has three individual parts, each having different
tasks:

1. The transformer is the part wherein the operating voltage is reduced. The mains voltage
(The electrical voltage supplied through mains power distribution) is applied to the
input of the transformer. A usable voltage is then produced at the output of the
transformer.
2. The rectifier is the part where the AC voltage from the reduced mains voltage is
converted into DC voltage. The capacitor after the rectifier diode smoothens the
voltage.
3. The stabilization is the part where voltage regulation occurs. The output voltage of the
PSU must be ensured to be constant regardless of the current flowing through.

Figure 3.1.1. Component parts of a power supply unit for an electro pneumatic controller
3.2 Push button and control switches

Switches are applied into the switches to either let the current flow through or stop the
current from flowing through. Switches are divided into two categories which are the
pushbuttons and control switches.

● Depending on the type, control switches are mechanically detented. The switch’s
position remains the same until a new switch position occurs. Examples of these types
of switches are light switches in our house.
● Push button switches are switches that maintain position as long as you press the
switch. Examples of these types of switches are bell push.

Normally open contact (make)

Figure 3.2.1 Normally open contact (make)

The circuit is open in the case of a typically open contact if the switch is in its original
position. By pressing the push button, the circuit is closed and current flows to the load. When
you let go of the plunger, the spring restores the switch to its original position, breaking the
circuit.
Normally closed contact (break)

Figure 3.2.2. Normally open contact (break)

In this type of switch, it is normally close or the initial position of the switch is close implying
that the circuit is complete. When you press the button or turn on the switch, the circuit is
interrupted.

Changeover contact

Figure 3.2.3. Changeover contact

In this case, the normally open and normally closed contacts are combined together into one
device. In a single switching operation, changeover contacts are utilized to close one circuit
and open another. During changeover, the circuits are briefly interrupted.

3.3 Sensors for measuring displacement and pressure

In electro pneumatic controllers, sensors play a crucial role in measuring information

and transmitting it to the signal processing component in a format that can be easily handled.
The main objectives of utilizing sensors in these controllers are as follows:

● To detect the advanced and retracted end position of the piston rod in cylinder
drives
● To detect the presence and position of workpieces
● To measure and monitor pressure

Limit switches

Figure 3.3.1. Mechanical limit switch: construction and connection possibilities

 A limit switch is triggered when a specific position of a machine part or workpiece is
reached. Typically, this activation is achieved through the use of a cam mechanism. Limit
switches commonly consist of changeover contacts, allowing them to be connected in different
configurations based on the desired functionality. This means they can be utilized as a normally
open contact, normally closed contact, or changeover contact depending on the specific
requirements.

Proximity switches

Unlike limit switches, proximity switches function without physical contact or the need for
external mechanical force. This contactless operation allows proximity switches to possess
extended durability and enhanced switching reliability. Various types of proximity switches are
distinguished, namely:
● Reed switch
● Inductive proximity switch
● Capacitive proximity switch
● Optical proximity switch

Reed switch

Reed switches are proximity switches that operate through magnetic activation. They
consist of two contact reeds housed within a glass tube that is filled with inert gas. When a
magnetic field is applied, the reeds come into contact, allowing electric current to pass through.
In the case of reed switches designed as normally closed contacts, the contact reeds are held
closed by small magnets. However, the stronger magnetic field generated by the switching
magnets overcomes this magnetic force, causing the reeds to open.

One notable advantage of reed switches is their extended lifespan, and they offer rapid
switching times of approximately 0.2 milliseconds. They require no maintenance, but it is
important to avoid deploying them in environments with strong magnetic fields, such as in
close proximity to resistance welders.

Figure 3.3.2. Reed switch (normally open contact)

Electric Sensors

Inductive, optical, and capacitive proximity switches are examples of electronic sensors
that are commonly employed. These sensors typically consist of three electrical contacts.
1. Contact for supply voltage
2. Contact for ground
3. Contact for output signal

These sensors operate without the need for a movable contact to be activated. Instead,
the output is designed to either establish an electrical connection with the power source or be
connected to ground, resulting in an output voltage of 0 V.

Positive and negative switching sensors

There are two categories of electronic sensors based on the polarity of their output voltage.
 ● Positive switching sensors have a zero output voltage when no object is detected
nearby. When a workpiece or machine part approaches, the output switches, resulting in
the application of the supply voltage.
● Negative switching sensors apply the supply voltage to the output when no object is
detected in proximity. When a workpiece or machine part approaches, the output
switches, causing the output voltage to become 0 V.

Inductive proximity sensors

An inductive proximity sensor consists of three main components: an electrical

oscillator (1), a flip-flop (2), and an amplifier (3). When a voltage is applied, the oscillator
generates a high-frequency magnetic field that is emitted from the front of the sensor. If an
electrical circuit enters this field, it causes a reduction in the oscillator's strength. The
subsequent circuitry, which consists of a flip-flop and an amplifier, analyzes the oscillator's
behavior and triggers the output accordingly. Inductive proximity sensors are capable of
detecting all types of good electrical conductors. This includes metals as well as other materials
like graphite.

Figure 3.3.3. Inductive proximity sensor

Capacitive proximity sensors

A capacitive proximity sensor comprises a capacitor and an electrical resistance that

jointly create an RC oscillator, along with a frequency evaluation circuit. When the capacitor's
anode and cathode generate an electrostatic field, a stray field is formed at the sensor's front. If
an object enters this stray field, it alters the capacitance of the capacitor, resulting in attenuation
of the oscillator. The circuitry then switches the output.

Capacitive proximity sensors are not limited to detecting highly conductive materials
like metals; they can also respond to insulating materials with high dielectric strength such as
plastics, glass, ceramics, fluids, and wood.

Figure 3.3.4. Capacitive proximity sensor

Optical proximity sensor

Optical proximity sensors employ optical and electronic techniques to detect objects.
They utilize either red or infrared light, with semiconductor light-emitting diodes (LEDs) being
highly reliable sources of such light. LEDs possess qualities like compactness, durability, long
lifespan, and easy modulation. Photodiodes or phototransistors are employed as receivers in
these sensors. Red light offers the advantage of being visible during the adjustment of the
optical axes of the proximity switch. Additionally, polymer optical fibers can be used due to
their minimal light attenuation at this wavelength.

Three distinct categories of optical proximity switches can be distinguished:

1. One-way light barrier
2. Reflective light barrier
3. Diffuse reflective optical sensor

One-way light barrier

Figure 3.3.5. One-way light barrier

The unidirectional light barrier consists of physically separate transmitter and receiver
units, which are positioned in a manner where the transmitter emits a beam towards the
receiver. The output of the system is triggered when the beam is obstructed or interrupted.
Reflective light barrier

Figure 3.3.6. Reflective light barrier

In the reflective light barrier, the transmitter and receiver are mounted together in one
housing. The reflector is mounted in such a way that the light beam transmitted by the
transmitter is practically completely reflected to the receiver. The output is switched if the
beam is interrupted.

Diffuse reflective optical sensor

Figure 3.3.7. Diffuse reflective optical sensor

The diffuse reflective optical sensor combines the transmitter and receiver into a single
unit. When light encounters a reflective object, it is redirected towards the receiver, triggering a
switch in the sensor's output. Due to its operating principle, the diffuse reflective optical sensor
is suitable for use only when the material or machine component being detected has a high
level of reflectivity. Examples of such surfaces include polished metal and bright paint.

Pressure Sensors

There are various types of pressure-sensitive sensors:

● Pressure switch with mechanical contact
● Pressure switch with electronic switching
● Electronic pressure sensor with analogue output signal

1. Mechanical Pressure Switch

Pressure operates on a cylinder surface in a pressure switch that is mechanically
activated. The piston advances and activates the contact set if the pressure applied
exceeds the return spring's spring force.

2. Electronic Pressure Switch

The significance of diaphragm pressure switches is increasing. The output is switched
electrically rather than being activated by a mechanical contact. The diaphragm is
equipped with sensors that are force- or pressure-sensitive. An electronic circuit
evaluates the sensor signal. The output is switched as soon as the pressure reaches a
particular level.

3. Analogue Pressure Sensors

The design and mode of operation of an analogue pressure sensor is demonstrated using
the example of the Festo SDE-10-10V/20mA sensor
Figure 3.13 Construction and characteristic curve of an analogue pressure sensor
(Festo SDE-10-10V/20mA sensor)
3.4 Relays and Contactors

A relay is an electromagnetically actuated switch. An electromagnet field forms when

voltage is delivered to the solenoid coil. This causes the armature to be attracted to the coil
core. Depending on the design, the armature will either close or open the relay contacts. When
the current to the coil is cut off, a return spring causes the armature to return to its starting
position.

Figure 3.14 Construction of a Relay

Applications of Relays:

In electro pneumatic control systems, relays are used for the following functions:
● Signal multiplication
● Delaying and conversion of signals
● Association of information
● Isolation of control circuit from main circuit In purely electrical controllers, the relay is
also used for isolation of DC and AC circuits

Retentive Relay

The retentive relay responds to current pulses:

● The armature is energized when a positive pulse is applied.
 ● The armature is de-energised when a negative pulse is applied.
● If no input signal is applied, the previously set switch position is retained.

The behavior of a retentive relay is analogous to that of a pneumatic double pilot valve, which
responds to pressure pulses.

Time Relay

There are two types of time relay – pull-in delay and drop-out delay.

1.) Pull-in delay - the armature is energized after a set delay

2.) Drop-out delay - is affected without delay.
 Figure 3.15 Relay with pull- in delay

Upon activation of switch S1, current passes through variable resistor R1 to C1 is a cap. Diode
D1 prevents current flow when connected in parallel. to move in this manner. Moreover,
current travels through discharge resistor R2. Once capacitor C1 has been charged the K1
relay's switched position; the relay switches. S1 is removed, interrupting the circuit, which
causes the capacitor to discharge quickly through diode D1 and resistor R2. Consequently, the
relay immediately goes back to its starting place.
The capacitor's charging current can be adjusted due to the variable resistor R1. Altering the
time until the K1 switching voltage as a result is attained. A big resistance causes a small
current to flow, which lengthens the delay. A significant current flows when the resistance is
low. and there is little delay.

Figure 3.16 Relay with drop-out delay

Construction of a Contactor

Contactors operate in the same way as a relay. Typical features of a contactor are:
 ● Double switching (dual contacts)
● Positive-action contacts
● Closed chambers - These design features allow contactors to switch much higher
currents than relay

Figure 3.17 Construction of a contactor

Multiple switching elements, typically four to ten contacts, are present in a contactor. There are
different types of contactors, similar to relays, with combinations of typically open contact,
normally closed contact, and changeover. delayed usually closed contact, etc. only-switching
contactors Contactor relays are auxiliary contacts. Main or power contactors are defined as
having both main and auxiliary contacts.

Application of Contactors

Contactors are used for the following applications:

 ● Currents of 4 to 30 kW are switched via the main contacts of power contactors.
● Control functions and logical associations are switched by auxiliary contacts. In electro
pneumatic controllers, electrical currents and power are low. For this reason, they can
be implemented with auxiliary contactors. Main or power contactors are not required

3.5 Programmable Logic Controllers

PLC are employed in binary control systems to process signals. Likewise, the PLC is
specifically ideal for binary control systems that require complicated signal combinations and
have a large number of input and output signals.

Figure 3 the Programmable Logic Controller

 Figure 3.1 System Components of a PLC

3.6 Overall Structure of the Signal Processing Part

Figure 3.2 Signal Control Section of Relay Control System

● Signal input takes place via two sensors or via push button or control switches.
Fig. 3.2 shows two proximity switches for signal input.
 ● Signal processing is normally undertaken by a relay control system or a
programmable logic controller. Other types of controller can be neglected. In
Fig. 3.2 control is undertaken by a relay control system.

● Signal output is via solenoid-actuated directional control valves.

Figure 3.3 Signal Control Section with PLC

Figure 3.3 shows the signal control section of an electropneumatic control system in
which a PLC is used for signal processing.

● The components for signal input (in Fig. 3.21: inductive proximity switches 1B1
and 1B2 are connected to the inputs of the PLC (I1, I2).
● The programmable microprocessor system of the PLC undertakes all signal
processing tasks.
● The components for signal output (in Fig. 3.21: solenoids of directional control
valves 1Y1 and 1Y2) are connected to the PLC outputs (O1, O2 etc.). They are
actuated by electronic circuits that are part of the microprocessor system