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PNEUMATICS CIRCUIT DESIGN

First Edition

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ALL RIGHTS RESERVED.
No part of this publication may be reproduced, distributed or transmitted in any
form or by any means, including photocopying, recording or other electronic or
mechanical methods, without the prior written permission of Politeknik Sultan
Salahuddin Abdul Aziz Shah.

PNEUMATICS CIRCUIT DESIGN

Dr. Mohd Elias Daud
Nazratulhuda Binti Awang@Hashim
ISBN No: e ISBN 978-967-2044-85-7

First Published in 2021 by:

UNIT PENERBITAN
Politeknik Sultan Salahuddin Abdul Aziz Shah
Persiaran Usahawan,
Seksyen U1,
40150 Shah Alam
Selangor

Telephone No. : 03 5163 4000

Fax No. : 03 5569 1903

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 PREFACE

Pneumatics technology is one of the important part in automation

system. It can be divided into two; fully pneumatic and electro-pneumatic
control. The learning system is therefore broken down in this chapter
focuses only fully pneumatic system as follows:

• The components of the pneumatic

• Basic control in pneumatic system
• Single cylinder control
• Multiple cylinder control
• Pneumatic accessories

The learning system for pneumatic technology is continuously updated

and expanded in accordance with developments in the field of education,
as well as actual professional practice. This training packages deal with
various component of pneumatic and very helpful for engineering
technician for maintenance of the machine part.

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 1.0 Pneumatics Circuit Design

1.1 Movement for One Cylinder

1.1.1 Pneumatic circuit diagram for one cylinder

based on:
CONTENTS OF THIS TOPIC

a. Direct control
b. Indirect control

1.1.2 Pneumatic circuit diagram:

a. Dual pressure valve (AND Function)
b. Shuttle valve (OR Function)
c. 5/2-way double pilot valve
d. Pressure sequence valve
e. Time delay valve

1.1.3 Design the pneumatic circuit diagram

based on task given.

1.2 Development of Multiple Cylinder Circuits

1.2.1 Sequence control for numerous cylinder

a. Coordinated motion
b. Displacement step diagram

1.2.2 Circuit solution for overlapping signals

a. Roller lever valve with Idle return solution
b. Reversing valve solution (Cascade)

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1.0 Introduction

The Pneumatic system supported with

several components, which is consist of
Air generation unit, Input unit, Control
unit, Processing unit and Actuating Unit
(Figure 1). In this section all pneumatic
component will be discussed.

Figure 1: Pneumatic Circuit Flow

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 1.1 Directional Control valve Symbols

➢ Directional control valve is

represented by the number
of controlled connections,
the number of positions and
the flow path.
➢ Numbering system is used to
designate directional control
valves and is in accordance
with DIN ISO 5599-3 (Figure
2).
➢ Working lines :

Figure 2: Directional Control Valve (DCV) Port

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Figure 3: The Type of DCV

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Figure 4: Valve Operation Method

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 1.2 Pneumatic Cylinder

Pneumatic cylinders can be

controlled by the following
methods:

A. Direct control of Single and Double acting

cylinder
B. Indirect Control of Cylinder with Single Piloted
Final Control Valve
C. Indirect Control of Cylinder with Double Piloted
Final Control Valve
D. In the indirect control actuation, a pilot signal
from a 3/2 N.C. valve is used to
E. activate pilot ports of final control valve.

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A. Direct control of Single and Double Acting Cylinder

1. Direct control of Single Acting Cylinder

➢Direct control of single acting cylinder consist of
single acting cylinder and 3/2 DCV valve push button
with spring return (Figure 5).
➢By pressing a Push Button, cylinder move forward,
by releasing a Push Button, the cylinder back to its
retract position.

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Figure 5: Direct Control of Single Acting Cylinder
2. Direct control of Double Acting Cylinder
➢Figure 6 shows a double acting cylinder controlled
by pressing a push button.
➢Direct control of double acting cylinder consist of
double acting cylinder and 5/2 DCV valve push
button with spring return.
➢By pressing a Push Button, cylinder move forward,
by releasing a Push Button, the cylinder back to its
retract position.

Figure 6: Direct Control of Double Acting Cylinder

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B. Indirect control of Single and Double Acting
Cylinder

1. Indirect control of Single Acting Cylinder

➢Indirect control of single acting cylinder consist of
single acting cylinder and 3/2 DCV valve push button
with spring return and Final control valve (3/2 DCV, air
operated)(Figure 7).
➢By pressing a Push Button, cylinder move forward,
by releasing a Push Button, the cylinder back to its
retract position.

Figure 6: Direct Control of Double Acting Cylinder

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2. Indirect control of Double Acting Cylinder
➢ Indirect control of single acting cylinder consist
of single acting cylinder and 3/2 DCV valve push
button with spring return and Final control valve
(5/2 DCV, air operated)(Figure 8)
➢ By pressing a Push Button, cylinder move
forward, by releasing a Push Button, the cylinder
back to its retract position.

Figure 8: Indirect Control of Double Acting Cylinder 14

1.2.1 Pneumatic circuit diagram

a. Dual pressure valve (AND

Function)
➢ Used for safety function; normally
used in Pressed machine.
➢ Needs a two switches
➢ The dual-pressure valve is switched
through to the output by applying
compressed air to both of the inputs
(AND function). (Festo)

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Figure 9: AND valve Function
1.2.1 Pneumatic circuit diagram

b. Shuttle valve (OR Function)

➢ Used for parallel application
➢ A shuttle valve, it allows pressure in a line to be
obtained from alternative sources. It is consists
of a ball inside a cylinder, as shown in Figure 10.
➢ If pressure is applied to port X, the ball is
blown to the right, blocking port Y and linking
ports X and Z. Similarly, pressure to port Y alone
connects ports Y and A and blocks port X.
➢ The Shuttle valve is switched through to the
output by applying compressed air to either
one of the inputs (OR).

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 Figure 10: OR Valve

Figure 11: OR Function Circuit

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 1.2.1 Pneumatic circuit diagram

c. 5/2-way double pilot valve

➢ Valve 1V1 has double pilot, which, signal of 14
and 12 .
➢ For Extending action, signal 14, switch 1S1
supplied to the valve
➢ For Retracting action, signal 12, switch 1S2
supplied to the valve

Figure 12: Double Air Operated Valve 18

 d. Pressure sequence valve
➢ The sequence valve is a close relative of the pressure-relief valve
and is used where a set of operations are to be controlled in a
pressure-related sequence. A Figure 13 shows a typical example
where a workpiece is pushed into position by cylinder B and
clamped by cylinder A.
➢ Sequence valve V2 is connected to the extend line of cylinder B.
When this cylinder is moving the workpiece, the line pressure is
low, but rises once the workpiece hits the end stop. The sequence
valve opens once its inlet pressure rises above a preset level.

Figure 13: Sequence Valve

➢Cylinder A then operates to clamp the workpiece. DCV valve (1.3)

allows both cylinders to retract together through signal 12 of 5/2 DCV.
➢The construction of a sequence valve. In many respects it is a variation
on a relief valve, the main difference being leakage in a sequence valve
drains to tank rather than to the outlet port.
➢The valve is a two-way valve which is held closed by an adjustable
pressure-setting spring. When the set pressure is reached the force from
the pressure acting on the left-hand side of the spool overcomes the
force of the spring and the spool moves to the right. Fluid now flows to
the secondary circuit. Hydraulic sequence valves should not be confused
with the pneumatic modular sequence valve of Figure 8.22.
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1.2.1 Pneumatic circuit diagram

e. Time Delay Valve

➢ Used to delay a pneumatic signal
➢ Used to control the pilot operated valve.
➢ Figure 14 shows how the air controlled through combination
valve (1V2). After a few second the pressure achieve a
required pressure, in order to activate 3/2 valve, then the
signal goes to 12 through 5/2 valve (1v3). The Cylinder 1A will
retract.

Figure 14: Time Delay Valve

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 Question: Design the pneumatic circuit diagram based on task given.

A double-acting cylinder is used to clamp components on a drill machine. Upon

operation of a push button and its in start position, the clamping cylinder
extends. Once the fully advanced position is reached and finish button is
pressed, the cylinder is then immediately retract to the initial position. The
cylinder retraction is to be adjustable. A new start cycle is only possible after the
cylinder has fully retracted.

Figure 15: The Application of Time Delay Valve

Answer: The Solution of Double Acting Cylinder Circuit

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Figure 16: The Solution of Double Acting Cylinder Circuit

2.2 Development of Multiple Cylinder Circuits

2.2 Development of Multiple Cylinder Circuits

2.2.1 Sequence control for numerous cylinder

a. Abbreviated notation
Is another possibility of representing motion sequences.
In this case, the cylinder designations A, B, C , etc. are used
in the sequence. In Figure 17 shows the nota The sequence
A+ B+ B- A- ; is to be read as follows: Cylinder A+
forward/extend, cylinder B forward, cylinder B retracts,
followed by cylinder A retracts. Sequential movements are
written consecutively.
The signal for Extending position is designated using a
position ‘+’ and the signal for retracting using a negative ‘-‘.
Hence, a small letter (a1, a2, b1, b2) representing a roller
switch or limit switch.

Figure 17: Abbreviated Notation of The Sequence Circuit

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b. Motion / Displacement step diagram

c. Displacement-Time –
Diagram
- In the case of a
displacement-time
diagram, the
displacement is plotted
in relation to the time.

Figure 18: Displacement Step & Time Diagram

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 EXERCISE ON:

CIRCUIT DESIGN
AND
CASCADE DESIGN

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 Example 1:

2.2.2 Circuit solution for overlapping signals

a. Roller lever valve with Idle return solution

Two cylinders (Fig 19) are used to transfer parts from a magazine onto a
chute.
When a push button is pressed, the first cylinder extends, pushing the
part from the magazine and positions it in preparation for transfer by the
second cylinder onto the outfeed chute. Once the part is transferred, the
first cylinder retracts, followed by the second. (Festo Didactic)

Figure 19: The Sequence Motion

Prepared by Dr. Mohd Elias B Daud,

PSA25
 Solution:

i. Propose a sequence diagram.

i. Setup a complete circuit diagram of pneumatic systems.

Figure 20: The Sequence Diagram (without overlapping)

 Example 2:

2.2.2 Circuit solution for overlapping signals

a. Roller lever valve with Idle return solution

A clamping system (double acting cylinder, (A) and drilling (double acting cylinder, B)
function as follows. When the switch is pressed, the clamps will clamp and drill the work
piece. Once completed, the drill will stopped and reversed. Finally, the clamps will
release the work piece. The limit of start and extend position of the clamps and drills are
determined by the limit switch a0 and a1 for clamping system and b0 and b1 for drilling
respectively.

Solution:

i. Propose a sequence diagram.

Figure 21: The Sequence Diagram

 Solution:

2.2.2 Circuit solution for overlapping signals

a. Roller lever valve with Idle return solution

Solution:

i. Setup a complete circuit diagram of pneumatic systems as in Fig 22.

Figure 22: The Solution of The Sequence Circuit (with overlapping signal)

Prepared by Dr. Mohd Elias B Daud,

PSA28
PNEUMATICS CIRCUIT DESIGN

b. CASCADE METHOD

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How to Develop Multiple-actuator Pneumatic
Circuits Using the Cascade Method?

STEP OVERVIEW:
➢ STEP 1 - Draw a notational form of the Control Task and group of
cascade
➢ STEP 2- Draw a displacement-step Diagram
➢ STEP 3 - Developing the Power Circuit
➢ STEP 4 - Draw the group supply to change of group 2, 3 or 4
➢ STEP 5 - Circuit Position during the A+ B+ B- A-
PROBLEM

Cylinder B
b1

b2

a1 a2

Cylinder A

Figure 23: The Application of Pneumatic

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 A Group of Pneumatics Sequence

Draw a notational form of the Control Task and

group of cascade
• The sequence of operations of cylinders, that is, A+ B+ B- A- are divided into
appropriate groups in such a way that there is no possibility of a signal conflict.
• Remember, A+ and A- can’t be in the same group, there is a possibility of signals
appearing simultaneously at both ends of the final control element.
• Similarly, B+ and B- can’t be in the same group, there is a possibility of signals
appearing simultaneously at both ends.
• Hence, the sequence of operations is divided in such a way that the A+ and A-
actions fall into different groups (K1 and K2), and the B+ and B- actions fall into
different groups (K1 and K2), as demonstrated.

Figure 24: The Abbreviated Notation and Group

 • A displacement step diagram illustrates how the
sequence of movements of the pneumatic control
system functions in a clear and easily understood
fashion.
• The individual movements of all the working
components are plotted along an axis that shows
the individual steps (Step 1 to 5 as example).
• The displacements of cylinders are plotted in
accordance with the required sequence of the
cylinder actions in equal steps.
Draw a Displacement-step

• The displacement of any cylinder from the

retracted position (0) to the extended position
(1) is shown in the diagram with a line from 0 to
1.
Diagram

Displacement Step-Diagram Timing Diagram

Figure 25: The Displacement Step & Time Diagram

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 Developing The Power Circuit

➢ The designing of a circuit diagram for the control task is to draw the
power circuit with the cylinders, final control elements, and properly
designated sensors. Two 5/2-way double-pilot valves act as final
control elements to control the cylinders A and B respectively.
➢ For the automatic operation of the desired sequence, a pair of
sensors is used per cylinder to confirm the end positions of the
piston. Sensors a1 and a2 are positioned in the retracted and
extended positions respectively of the cylinder A.
➢ Similarly, sensors b0 and b1 (or B0 and B1) are positioned in the
retracted and extended positions respectively of the cylinder B. The
partial circuit with the cylinders, the final control elements, and the
sensors are shown in the figure.

➢ The entire sequence of the

cylinder actions and the
associated sensor outputs can
be represented in a notational
form before developing the
control circuit. The developed
circuit is then checked for the
presence of signal conflicts.

Figure 26: Development of Power Circuit

Developing The Power Circuit

➢ The entire sequence of the

cylinder actions and the
associated sensor outputs can
be represented in a notational
form before developing the
control circuit. The developed
circuit is then checked for the
presence of signal conflicts.

Figure 27: Development of Power Circuit

 • Divide the power supply for the control circuit
into an equal number of groups in such a way that
at any given point in time, only one group will
have the supply with all other group(s) connected
to the exhaust.
• By an appropriate interconnection of the 5/2-DC
valves, the power supply can be divided into 2
groups, 3 groups, 4 groups etc.
• It should be remembered that the desired
Draw the group supply to
change of group 2, 3 or 4

sequence should be maintained. In this method,

every attempt should be made to keep the
number of groups to a minimum so as to keep the
number of valves to a minimum.

2 GROUP

Figure 28: The Development of Group 2, 3 or 4

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 3 GROUP
Draw the group supply to
change of group 2, 3 or 4

4 GROUP

Figure 29: The Development of Group 2, 3 or 4

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 Circuit Position during the A+ B+ B- A-
• When the “Start” pushbutton is pressed, the air supply from the
group G2 is directed to the port 14 of the reversing valve 0.1 through
the “Start” pushbutton and the actuated sensor a0.
• The reversing valve switches over causing the group supply to change
from the group G2 to G1. (Note: a0 is shown in the released position
due to the subsequent extension of cylinder A).
• When the group is changed from the group G2 to G1 with the group
G2 vented, the air supply from the group G1 is directed to port 14 of
the valve 1.1. As there is no possibility of a signal conflict here, the
valve 1.1 switches over causing the A+ action.

Circuit Position
during the A+
Action

Figure 30: The Circuit Positioning

Circuit Position during the A+ B+ B- A-

Circuit Position
during the B+
Action

Figure 31: The Circuit Positioning

Prepared by Dr. Mohd Elias B Daud,

PSA39
Circuit Position during the A+ B+ B- A-

b1- Circuit to change

power line from
Group 1 (K1) to Group
2 (K2)
Figure 32: The Circuit Positioning
Circuit Position during the A+ B+ B- A-

Circuit Position during

the B- Action

Figure 33: The Circuit Positioning

Circuit Position during the A+ B+ B- A-

Circuit Position
during the A- Action

Figure 34: The Circuit Positioning (Complete Circuit)

THE SEQUENCE OF THE PNEUMATICS CIRCUIT - COMPLETED

 PROBLEM
A transfer system, consist of two cylinder double acting
cylinder. Cylinder A will push part from the magazine,
then back to its start position. The Cylinder B start
moving forward when the Cylinder A fully retract. The
Cylinder B only retract when the component is fully
transferred onto the transfer box. The cycle is to start
when a start button is pressed.
EXERCISE

Figure 35: The Application of Pneumatic Circuit

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 STEP 1 - A Group of Pneumatics Sequence

SOLUTION

STEP 2 -Draw a Displacement-Step Diagram

EXERCISE

Figure 36: Draw a Group and Step Diagram

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 STEP 3 – Developing Power Circuit

SOLUTION
STEP 4 - Draw the group supply to change of group
2, 3 or 4
EXERCISE

Figure 37: The Group of 3

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 STEP 5 – Develop a Circuit Position For A+ A- B+ B-

SOLUTION
EXERCISE

Figure 38: The Development of Circuit Positioning

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SOLUTION STEP 5 – Develop a Circuit Position For A+ A- B+ B-
EXERCISE

Figure 39: A Complete Circuit

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 REFERENCES

1. Ebel F. (2013). Pneumatics Basic Level, Festo

Didactic GmbH & Co. KG, D-73770Denkendorf,
Germany
2. Totten G.E & De Negri V.J (2017). Handbook of
Hydraulic Fluid Technology,Second Edition. Taylor &
Francis Group.
3. The Pneu Book, SMC Pneumatics (UK) Ltd
4. Ilango Sivaraman (2017). Introduction to Hydraulics
and Pneumatics, 3rd Ed. PHILearning Pvt. Ltd. Delhi.
5. SMC Pneumatics (Australia) Pty Ltd (1996). SMCT.P1
Pneumatic Technology 1 Textbook
6. SMC Pneumatic (Hongkong) Limited. SMCT. C.A.T.
P1, SMC Training Softwarwe.

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