pneumatic electropnuematic jan2008
TRANSCRIPT
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2008 1
PNEUMATICS AND ELECTRO-PNEUMATICS TECHNOLOGY
UNIVERSITY KUALA LUMPURMALAYSIA FRANCE INSTITUTE
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2008 2
Principles of pneumatics
Pnuematics defined • Pnuema – Air (wind or breath in ancient Greek)
• Matic – movement
• It means control movement of air• In industries, it is referred as the used of compressed air to transmit power or/and motion
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2008 3
Principles of pneumatics
MOST ENERGY SOURCE
• Electricity• Hydraulics• Pneumatic• Etc
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2008 4
Principles of pneumatics
Why Pnuematic? The advantages:• Cheap – Air is available in unlimited
supply• Air is non-explosive and non-toxic• Compressed air can be transmitted over
long distance• Compressed air can be stored• Fast• Easily control the speed and movement• Clean• Overload proof
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2008 5
Principles of pneumatics
Disadvantages:• Air absorbs moisture and drying may
have to be considered• The exhaust air causes noise. Sound
absorbers may be required• Pressure limit which can be used in a
compressed air system• Smooth and even movement not
possible
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2008 6
Principles of pneumatics
Pneumatics is used in carrying out machining and working operations.For example:• Drilling• Turning• Milling• Sawing• Finishing• Forming• Quality control
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2008 7
Principles of pneumaticsApplication example: Conveyor line diverter
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2008 8
Principles of pneumatics
Application example: Pneumatic cutter
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2008 9
Principles of pneumatics
Unit for pressure• PSI• Pa• Bar (normally used in industries)• N/m2 (SI unit)
- Gauge pressure vs absolute pressure
- Vacum
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2008 10
Principles of pneumatics
ELEMENTS OF PNUEMATICS SYSTEM• Energy supply, source• Input elements, input signal• Processing elements, processor
signal• Final control element, control signal• Actuating devices, output
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2008 11
Principles of pneumatics
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2008 12
Principles of pneumatics
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2008 13
Electro-pneumatic System• Combination of electrical control and
pneumatic technologies
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2008 14
Electro-pneumatic System
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2008 15
Electro-pneumatic SystemAdvantages of electro-pneumatic:• Higher reliability (fewer moving parts
subject to wear)• Lower planning and commissioning
effort particularly for complex controls• Lower installation effort, particularly
when modern components such as valve terminal are used
• Simpler exchange of information between several controllers
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2008 16
Pnuematic System and Air Generation
ENERGY SUPPLY UNIT (AIR GENERATION)
• Air compressor• Air receiver/reservoir• Air cooler• Air dryer• Service unit – Filter, Regulator &
Lubricator (FRL unit)
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2008 17
Pnuematic System and Air GenerationCompressed air distribution system:
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2008 18
SYMBOL FOR ENERGY SUPPLY UNIT
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2008 19
SYMBOL FOR ENERGY SUPPLY UNIT
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2008 20
Energy Supply Unit
TYPE OF COMPRESSOR• Reciprocating
- piston- diaphragm
• Rotary- vane- screw
• Flow compressor- axial flow- radial flow
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2008 21
Energy Supply UnitType of compressor
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2008 22
ENERGY SUPPLY UNIT
Type of compressor
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2008 23
Type Of Compressor
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2008 24
Type Of Compressor
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2008 25
Air Drying
Refrigeration Drying
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2008 26
Refrigeration Drying
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2008 27
AIR DRYING
Absorption and Adsorption drying
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2008 28
ABSORPTION DRYING
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2008 29
ADSORPTION DRYING
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2008 30
ENERGY SUPPLY UNITSURVICE UNIT• Compressed air filter
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2008 31
COMPRESSED AIR FILTER
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2008 32
SERVICE UNIT
Pressure regulating valve
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2008 33
PRESSURE REGULATING VALVE
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2008 34
SERVICE UNITCompressed air lubricator
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COMPRESSED AIR LUBRICATOR
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2008 36
Pneumatic Symbols and Standard
Flow path
Switching position
Flow path blocked
Connection ports
Directional Control Valves
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2008 37
- Way valve
Number of ports
Number of switching positions
2 2
- Way valve32
Pneumatic Symbols and Standard
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2008 38
Pneumatic Symbols and Standard
Directional control valves
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2008 39
Pneumatic Symbols and Standard
Port designation
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Port designation
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2008 41
Input Elements ValveTypes of actuation
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Input Elements ValveTypes of actuation
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2008 43
Pneumatic Symbols and StandardNon-return, flow control and pressure control valves
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2008 44
Pneumatic Symbols and StandardNon-return, flow control and pressure control valves
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2008 45
Pneumatic Working Elements
Linear:• Single acting cylinder• Double acting cylinder• Rodless cylinder
Rotary:• Rotary actuator• Swivel drive/cylinder
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2008 46
Pneumatic Working Element
Single acting cylinder
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2008 47
Single Acting Cylinder
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2008 48
Single Acting Cylinder
Bellow / membrane cylinder
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2008 49
Pneumatic Working ElementDouble acting cylinder
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2008 50
Double Acting Cylinder
• With out cushioning
• With cushion
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2008 51
Cylinder Construction
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Type Of Mounting
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2008 53
Type Of Mounting
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Type Of Mounting
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Type Of Mounting
Rod end mountings
F
UF
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2008 56
Rodless Cylinder
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Rodless Cylinder
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2008 58
Rotary Cylinder & Swivel Drive
Swivel Drive
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2008 59
Rotary Cylinder & Swivel Drive
Rotary cylinder
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2008 60
Force CalculationPascal’s Law:pressure exists when a force F is imposed on an enclosed fluid with a surface A, The pressure exerts an equal effect on all points of the surfaces.
FP
A
P =FA
N/m2
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2008 61
Force CalculationTheoretical Force: Fth
Fth is the calculated force based on Pascal’s Law without consideration of all the resistance forces.
Frictional Resistance: Ff
To be considered during extend and retract strokes. Estimated at about 10 to 12% of Fth.
Spring Resistance: Fsp
To be considered when using spring loaded single acting cylinders. Estimated at about 15% of Fth.
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2008 62
Force Calculation
Example 1:A double acting cylinder is used to transfer work-pieces in a production machine. Determine the extend and retract forces if the piston diameter of the cylinder is 80mm, rod diameter 15mm and the pressure used is 6bar. Assume frictional force is 10% of theoretical force.
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2008 63
Force Calculation
Example 2:A clamping vice uses a single acting cylinder to clamp the work-pieces. Determine the extend force if the piston diameter of the cylinder is 80mm, rod diameter 15mm and the pressure used is 6bar. Assume frictional and spring forces are 10% and 15% of theoretical force respectively.
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2008 64
Design and construction of pneumatic control circuits
Exercise 1.
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2008 65
Design and construction of pneumatic control circuits
Exercise 2.
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Design and construction of pneumatic control circuits
Components designation
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Design and construction of pneumatic control circuits
Components designation: Example
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Design and construction of pneumatic control circuits
Direct and indirect actuation
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DIRECT ACTUATION
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INDIRECT ACTUATION
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2008 71
Pneumatic Control DevicesDirectional Control Valves
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Directional Control Valves
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Directional Control Valves
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Directional Control Valves
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Directional Control Valves
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Directional Control Valves
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Directional Control Valves
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Directional Control Valves
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Directional Control Valves
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Pneumatic Control DevicesShuttle Valve (OR)
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Shuttle Valve (OR)
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Pneumatic Control DevicesDual Pressure Valve (AND)
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Dual Pressure Valve (AND)
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Design and construction of pneumatic control circuits
EXERCISE 3.
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SHUTTLE VALVE (OR FUNCTION)
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Design and construction of pneumatic control circuits
EXERCISE 4.
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DUAL PRESSURE VALVE (AND FUNCTION)
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Pneumatic Control DevicesOne-way Flow Control Valve
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One-way Flow Control Valve
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One-way Flow Control Valve
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Design and construction of pneumatic control circuits
EXERCISE 5.
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5/2 WAY DOUBLE PILOT VALVE (SPEED CONTROL)
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Design and construction of pneumatic control circuits
Exercise 6. A container of washers is to be dipped in and out of the cleaning bath by using a double acting cylinder. The start and stop for this continuous movement is to be achieved by actuating the ‘START’ and ‘STOP’ pushbuttons each.On actuating the ‘STOP’ pushbutton, the container should stop at the top. The speed for forward and retract strokes are controllable.
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ELECTRO PNEUMATIC
Pneumatic Vs electro-pneumatic Electro-pneumatic component Electrical component Electro-pneumatic controller Design and construction of electro-
pneumatic control circuits
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Electro-pneumatic components
Function of solenoid A magnetic field is
induced when a current passed through an electrical conductor
A soft iron core (amature) is drawn into a coil through which the current is flowing
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Electro-pneumatic componentsSolenoid Valves
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Solenoid Valves
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Solenoid Valves
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Solenoid Valves
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Solenoid Valves
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Solenoid Valves
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Solenoid Valves
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Electrical components
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Electrical components
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Electrical components
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Electrical components
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Design and construction of elctro-pneumatic control circuits
Using a sorting device, parts are to be transferred from conveyor belt. By pressing the pushbutton switch, the piston rod of a single-acting cylinder pushes the part off the conveyor belt. When the pushbutton is released, the piston rod returns to the retracted end position.
Exercise 7:
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Design and construction of electro-pneumatic control circuits
Using a special device, the valve in a pipe line is to be opened and closed. The valve is opened by pressing the pushbutton switch. When the pushbutton is released the valve is closed.
Exercise 8:
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Design and construction of electro-pneumatic control circuits
Wooden planks are to be pushed along from a gravity feed magazine to a clamping device. By pressing a pushbutton switch one plank is pushed by the slide out of the gravity feed magazine. After the slide has reached the forward end position it is returned to its start position.
Exercise 9:
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Electrical components
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Design and construction of electro-pneumatic control circuits Exercise 10:
Using a conveyor belt, parts are to be transported in linear timed sequence to work stations which are arranged in line after one another. When the latching pushbutton (or selector) switch is activated the main wheel is indexed by the oscillating piston rod of a cylinder via a pawl. When the pushbutton (or selector) switch is activated again the drive is switched off.
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Electrical components
Coil
Coil connections
Contacts
Contact connections
Return spring
Cover
Symbol
A1
A2 11
12
14
21
22
24
Armature
Relay
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Relay
Symbol
A1
A2 11
1214
21
2224
A1 A2 4 2 1
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Relay
Symbol
A1
A2
11
1214
21
2224
A1 A2 4 2 1
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Design and construction of electro-pneumatic control circuits
Repeat the exercise 10 but the conveyor is controlled by using ‘Start’ and ‘Stop’ pushbuttons.
Exercise 11:
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Electro-pneumatic controller
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Electro-pneumatic controller
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Electro-pneumatic controller
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Electro-pneumatic controller
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Electro-pneumatic controller
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Electro-pneumatic controller
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Electro-pneumatic controller
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Electro-pneumatic componentsPressure Switch
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Design and construction of electro-pneumatic control circuits
Exercise 12:
Parts are to be stamped with a stamping device. By pressing two pushbutton switches the die is pushed down and the part is stamped. When the stamping pressure has been achieved the dieis returned to its start position.
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Electrical componentsTime relay (Timer)
Two types:•Pull-in (on) delay and •Drop-out (off) delay
Pull-in (on) delay
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Pull-in (on) delay Timer
Signal behavior:
Time relay (Timer)
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Drop-out (off) delay
Time relay (Timer)
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Time relay (Timer)Drop-out (off) delay
Signal behavior:
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2008 129
Design and construction of electro-pneumatic control circuits
Using a hot pressing die, packing material is to be sealed by application of heat. By pressing a pushbutton switch the heating rail is advanced and the packaging material is heated along the adhesive strip. After the adhesion time of 10 seconds has reached, the heating rail is returned to its start position.
Exercise 13:
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Design and construction of electro-pneumatic control circuits
Using a transfer station blocks are to be transferred from a magazine to a processing station.The blocks are pushed out of the magazine by cylinder 1A and transferred to the processing station by cylinder 2A. The piston rod of cylinder 2A may only return when the piston rod of cylinder 1A has reached the retracted end position. The magazine is monitored by means of a limit switch. If there are no more blocks in the magazine, it is not possible to start the cycle. This is indicated by means of an audible signal. The control is to be operated in single cycle.
Exercise 14:
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Control of Multiple Cylinders
Chronological sequence is simplified by using:• Displacement step diagram (pictorial)• Vector diagram
Example: 1A→ 2A→ 2A← 1A←• Abbreviation notation
Example: 1A+ 2A+ 2A- 1A-
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Design and construction of electro-pneumatic control circuits
Workpieces are inserted into the clamping device by hand. Clamping cylinder 1A is to extend when the start button is pressed. When the workpiece is clamped, it is to be drilled via feed unit 2A and the drill retracted once again. Then, the clamping cylinder 1A is to release the workpiece.
Exercise 15:
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Design and construction of electro-pneumatic control circuits
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Control of Multiple CylindersMethods for construction a circuit diagramTwo primary methods:
• Intuitive method - conventional or trial and error methods.
• Methodical design I accordance with prescribed rules and instructions.
Signal overlapsOvercome by signal cut-out through:1) Components
• Idle roller limit switch• Timer
2) Circuit• Electrical Cascading Circuit• Electrical Shift register
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THE ENDTHANK YOU