ELECTRO-PNEUMATICS AND ELECTRO-

HYDRAULICS

PRASHANTH B N
Assistant Professor
Department of Mechanical Engineering
Amrita School of Engineering
 INTRODUCTION TO ELECTRO-PNEUMATICS
 Electro-pneumatics is now commonly used in many areas of industrial low-cost
automation.
 It is also used extensively in production, assembly, pharmaceutical, chemical and
packaging systems.
 There has been a significant change in control systems; relays have increasingly been
replaced by programmable logic controllers (PLC) in order to meet the growing demand
for more flexible automation.
 Electro-pneumatic control consists of electrical control systems operating pneumatic
power systems.
 Solenoid valves are used as the interface between electrical and pneumatic systems.
 Devices like limit switches and proximity sensors are used as feedback elements.
 Electro-pneumatic control is more widely used for large applications.
 The signal medium in these systems is the electrical signal which is either AC or DC.
 INTRODUCTION TO ELECTRO-PNEUMATICS
 The working medium is compressed air.
 Operating voltages from around 12 V to 220 V are common and the final control valve is
activated by solenoid actuation.
 The resetting of the valve is either by spring valve (single solenoid) or using a double
solenoid valve.
 More commonly, the valve actuation and reset is achieved by a pilot assisted solenoid
actuation to reduce the size and cost of the valve.
 Control of electro-pneumatic systems is achieved using either using a combination of
relays and contactors, or with the help of Programmable Logic Controllers (PLC).
 A relay is often is used to convert signal input from sensors and switches to a number of
output signals (either normally closed or normally open).
 Signal processing can be easily achieved using relay and contactor combinations.
 INTRODUCTION TO ELECTRO-PNEUMATICS
 A programmable logic controller provides a convenient way to get output based on
specific requirements.
 The output signals are supplied to the solenoids activating the final control valves which
control the movement of the cylinders.
 The greatest advantage of electro-pneumatics is the integration of various types of
proximity sensors (electrical) and PLC for very effective control.
 As the signal speed with electrical signal is much higher, cycle time is reduced and signal
can be conveyed over long distances.
 Electro-pneumatic controls involve three important steps:
 Signal Generation using Input Devices - Signal is generated using devices such as
switches, contactors, and sensors.
 Processing of Signals - Signals are processed using contactors and relays, or
Programmable Logic Controllers (PLC).
 Signal Outputs - Output from signal processing units are used to activate output
devices like solenoids, indicators or audible alarms.
 CONTROL ELECTRICAL DEVICES
 Seven electrical devices are commonly used in the control of fluid power systems:
 Manually actuated push button switches
 Limit switches
 Pressure switches
 Solenoids
 Relays
 Timers
 Temperature switches

 Other devices also used in electro-pneumatics are:

 Proximity sensors
 Electric counters
 PUSH BUTTON SWITCHES
 A push button (PB) is a switch used to open or close an electric control circuit.
 It is primarily used for starting and stopping operation of machinery and also to provide a
manual override during emergencies.
 Push button switches are actuated by pushing the actuator into the housing causing a set
of contacts to open or close.
 Push buttons are of two types:
 Momentary push button
 Maintained contact or detent push button

 Momentary push buttons return to their unactuated position when they are released.
 Maintained push buttons have a latching mechanism to hold them in the selected position.
 PUSH BUTTON SWITCHES
Push buttons are also distinguished according to contact behaviour:
 Normally open (NO)
 The contacts are open in the normal position, disconnecting
energy flow through them.
 In the actuated position the contacts are closed, permitting
energy flow through them.
 Normally closed (NC)
 The contacts are closed in the normal position, permitting
energy flow through them.
 The contacts are open in the actuated position, disconnecting
energy flow through them.
 Change-over (CO)
 A change-over contact is a combination of NO and NC contacts.
PUSH BUTTON SWITCHES

Push buttons and their symbols

 LIMIT SWITCHES
 Any switch that is actuated by the position of a fluid power component (usually a piston
rod, a hydraulic motor shaft, or the position of a load) is termed a limit switch.
 The actuation of a limit switch provides an electrical signal that causes an appropriate
system response.
 Limit switches perform the same function as push button switches, with the difference
that they are mechanically actuated whereas push buttons are manually actuated.
 Limit switches are classified by the method of actuation of the contacts:
 Lever actuated: where contacts are operated slowly
 Spring loaded: where contacts are operated rapidly
 PRESSURE SWITCH
 A pressure switch is an electro pneumatic signal converter.
 It is used to sense a change in pressure, and opens or closes an electrical switch when a
predetermined pressure is reached.
 Bellows or diaphragms are used to sense the change of pressure and expand or contract in
response.
 Pressure is applied at the inlet and when the preset pressure level is reached, the
diaphragm expands and pushes the spring loaded plunger to make or break the contact.
 SOLENOIDS
 Electrically actuated directional control valves form the interface between the two parts
of an electro-pneumatic control.
 The main objectives of electrically actuated DCVs include:
 Controlling the air supply (turning it on or off)
 Extending and retracting the cylinder drives
 These DCVs are controlled with the aid of solenoids and can be divided into two groups:
 Spring return valves which remain actuated as long as current flows through the
solenoid
 Double solenoid valves which maintain the last switched position even when no
current flows through the solenoid
 In the initial position, all the solenoids of electrically actuated DCVs are de-energised and
inactive.
 A double solenoid operated valve has no specific initial position since it does not have a
return spring.
 The possible voltage levels for solenoids are: 12V DC, 12V AC, 12V 50/60Hz, 24V
50/60Hz, 110/120V 50/60Hz and 220/230V 50/60Hz.
 SOLENOIDS
3/2 Single Solenoid Valve, Spring Return
 In the normal position, port 1 is blocked and port 2 is connected to port 3.
 When the rated voltage is applied to the coil, the armature is lifted away from the valve
seat and pulled towards the centre of the coil.
 The compressed air now flows from port 1 to port 2, and port 3 is blocked.
 When the voltage supply to the coil is stopped, the valve returns to the normal position.
 SOLENOIDS
5/2 Single Solenoid Valve, Spring Return
 In the normal position, port1 is connected to port2, port4 to port5, and port3 is blocked.
 When the rated voltage is applied to coil 14, the valve is actuated through an internal
pilot valve.
 In the actuated position, port1 is connected to port4, port2 to port3, and port5 is blocked.
 Valve returns to the normal position when the voltage to the armature coil is removed.
 This type of valve is normally used as the final valve to control double acting cylinders.
 SOLENOIDS
5/2 Double Solenoid Valve
 When the rated voltage is applied to coil 14, the valve is actuated to one switching
position with port 1 connected to port 4, port 2 connected to port 3, and port 5 blocked.
 When the rated voltage is applied to coil 12, the valve is actuated to the other switching
position with port 1 connected to port 2, port 4 connected to port 5, and port 3 blocked.
 SOLENOIDS
Various Symbols for Direct Control Solenoid Valves
 RELAYS
 An electromagnetically actuated switch used in signal processing.
 Designed to withstand heavy power surges and harsh environmental conditions.
 When voltage is applied to a solenoid coil, an electromagnetic field is created which
causes the armature to be attracted to the coil core.
 Armature actuates relay contacts by either opening or closing them, depending on the
design.
 A return spring restores the armature to its initial position when current to the coil is
interrupted.
 TIME DELAY RELAYS (TIMERS)
 Timers are required in control systems to introduce time delays between work operations
via the associated control element.
 Electronic timers are most commonly used.
 There are two types of time delay relays:
 Pull-in delay (on-delay timer) – The timer does not give the contact changeover
until the preset time reached.
 Drop-out delay (off-delay timer) - The timer is ready to accept the trigger when
the input voltage is applied.
 TEMPERATURE SWITCH
 Temperature switch automatically senses a change in the temperature and opens or closes
an electrical switch when a predetermined temperature is reached.
 It can be wired to be either normally open or normally closed.
 Temperature switches can be used to protect a fluid power system from serious damage
when a component such as a pump, strainer or cooler begins to malfunction.
 REED PROXIMITY SWITCHES
 Reed switches are magnetically actuated proximity switches and are similar to relays,
except a permanent magnet is used instead of a wire coil.
 A reed switch comprises two ferromagnetic reeds placed in a hermetically sealed glass
tube with a gap between them.
 The glass tube is filled with inert gas to prevent the activation of the contacts.
 The surfaces of the reed contacts are plated with rhodium or iridium.
 The entire unit is encapsulated in epoxy resin to prevent mechanical damage to the
switch, and an LED indicator displays the switching status.
 REED PROXIMITY SWITCHES
Advantages of reed switches
 Reed switches are cheap
 They have a long service life
 They have shorter switching times (0.2 to 0.3 milliseconds)
 They are compact and maintenance-free

Disadvantages of reed switches

 Cannot be used in environments with magnetic fields (like resistance welding machines)
 Closing of contacts in a reed switch is not bounce-free
 ELECTRIC COUNTERS
 An electric counter consists of a coil, associated circuits and contacts, a reset coil, manual
reset, a release button and a display window.
 To preset the counter value, the release button of the counter is pressed and the desired
value is entered.
 The counter valve is displayed in the window.
 There are two types of counters: up and down.
 ELECTRIC COUNTERS
 Up Counter
 An up counter counts electrical signals upwards from zero.
 For each electrical pulse input to the coil, the counter value is incremented by 1.
 When the predetermined valve has been reached, the relay picks up and the contact
set is actuated.
 Down Counter
 A down counter counts down electrical signals from a preset valve.
 When the count reaches zero the relay picks up and the contact set is actuated.
 The counter can be reset manually by pressing the reset button or electrically by
applying a reset pulse to the reset coil.
 The preset value is maintained when the counter is reset.
 ELECTRONIC SENSORS
 Inductive, optical and capacitive proximity switches are electronic sensors.
 They normally have three electrical contacts, one for supply voltage, the second for
grounding and the third for the output signal.
 No movable contact is switched in this type of sensor.
 Instead, the output is either electrically connected to the supply voltage or to the ground.
 Based on the polarity of output voltage, electronic sensors can be classified as:
 Positive Switching Sensors - The output voltage is zero if no part is detected
nearby. The approach of a workpiece or machine part leads to the switch-over of the
output and application of supply voltage.
 Negative Switching Sensors – The supply voltage is applied to the output if no part
is detected nearby. The approach of a workpiece or machine part leads to switch-
over of the output, switching the output voltage to zero.
 ELECTRONIC SENSORS
Inductive Sensors
 Uses current induced by magnetic fields to detect nearby metal objects.
 In addition to metals, graphite can also be sensed.
 It uses a coil or inductor to generate a high frequency magnetic field.
 If there is a metal object near the changing magnetic field, current flows into the object.
 The current flow sets up a new magnetic field that opposes the original field.
 The net effect is a change in the inductance of the coil in the inductive sensor.
 By measuring this change, the sensor detects the presence of metal nearby.
 ELECTRONIC SENSORS
Inductive Sensors
 Advantages:
 Self-contained, rugged and extremely reliable
 Have a long service life
 Have shorter switching times
 Compact and maintenance-free
 Disadvantages:
 Cannot be used in environments with magnetic fields (resistance welding machine)
 Applications:
 Sensing the end position of linear actuators (cylinders, semi-rotary actuators)
 To detect metallic pieces (or their absence) on conveyors
 To detect the end position in a press
 To monitor breakages during drilling
 Used to provide feedback in speed measuring devices
 ELECTRONIC SENSORS
Capacitive Sensors
 Able to detect most materials at distances up to a few centimetres.
 The proximity of any material near the electrodes increases the capacitance in a
capacitive sensor.
 The increased capacitance varies the magnitude of the oscillating signal and the detector
decides when it is great enough to determine proximity.
 These sensors work well for insulators (such as plastics) that tend to have high dielectric
coefficients, thus increasing the capacitance.
 ELECTRONIC SENSORS
Capacitive Sensors
 Advantages:
 They are widely used because of their ability to react with a wide range of materials
 They are suitable for detecting non-metallic objects
 They can be used to sense and monitor levels in storage containers
 Disadvantages of proximity sensors
 They are sensitive especially in humid environments
 Without the compensator ring, the sensor is very sensitive to dirt, oil and other
contaminants that might stick to the sensor
 ELECTRONIC SENSORS
Optical Sensors
 Optical sensors require emitter and detector.
 Emitters emit light using LED or laser diodes.
 Photodiodes or phototransistors are commonly used detectors.
 A beam is transmitted from a emitter and it is received by a receiver.
 If the object is not present between emitter and detector, the beam is not broken.
 If the beam then is broken the detector will indicate that an object is present.
ELECTRO-PNEUMATIC CIRCUITS FOR SINGLE ACTUATORS

Direct Control of Single Acting Cylinder

 Forward Stroke: The circuit is closed
when push button PB closes. The
compressed air flows from 1 to 2 of the
3/2 DCV to the cylinder, which travels to
the final forward position.
 Return Stroke: When push button PB is
released, the circuit is interrupted. The 3/2
valve switches back to its original
position. The compressed air in the
cylinder then exhausts through port 3 of
the DCV and the cylinder travels to the
final rear position.
ELECTRO-PNEUMATIC CIRCUITS FOR SINGLE ACTUATORS

Indirect Control of Single Acting Cylinder

 Forward Stroke: The circuit is closed when
push button PB closes which energises NO
relay K1. The compressed air flows from 1
to 2 of the 3/2 DCV to the cylinder, which
travels to the final forward position.
 Return Stroke: When push button PB is
released, the circuit is interrupted which
deenergises relay K1. The 3/2 valve
switches back to its original position. The
compressed air in the cylinder then
exhausts through port 3 of the DCV and the
cylinder travels to its final rear position.
ELECTRO-PNEUMATIC CIRCUITS FOR SINGLE ACTUATORS

Direct Control of Double Acting Cylinder

 Forward Stroke: The double acting
cylinder is controlled by a 5/2 valve. When
push button PB is pressed, coil Y is
energised and the DCV is activated. The
piston travels to the final forward position.
 Return Stroke: When push button PB is
released, the circuit is interrupted. The
return spring of 5/2 becomes active and it
switches back to its original position. The
compressed air in the cylinder then exhausts
through port 5 of the 5/2 DCV and the
cylinder travels to the final rear position.
ELECTRO-PNEUMATIC CIRCUITS FOR SINGLE ACTUATORS

Indirect Control of a Double Acting Cylinder (5/2

Valve, Single Solenoid)
 Forward Stroke: The circuit is closed when push
button PB closes which energises relay K1 which in
turn indirectly energises coil Y. The compressed air
flows from 1 to 4 of the 5/2 DCV to the cylinder,
which travels to the final forward position.
 Return Stroke: When push button PB is released,
the circuit is interrupted which deenergises relay
K1. The 5/2 valve switches back to its original. The
compressed air in the cylinder then exhausts
through port 5 of the DCV and the cylinder travels
to the final rear position.
ELECTRO-PNEUMATIC CIRCUITS FOR SINGLE ACTUATORS

Indirect Control of a Double Acting Cylinder (5/2 Valve, Double Solenoid)

 Forward Stroke: When push button PB1 is pressed, coil Y1 is energised and the 5/2
DCV changes over. The piston travels out and remains in the final forward position
until a signal is applied to coil Y2. The 5/2 DCV remains in the last attained position
since it is a double solenoid valve with no return spring.
 Return Stroke: When push button PB1 is released and PB2 is pressed, PB1 de-
energises relay K1. The closing of PB2 energises Y2 and the piston returns to its
original position as a result of the changeover of the 5/2 valve. The 5/2 DCV does not
switch over if there is an active opposing signal. For example, if Y1 is switched on and
a signal is given to Y2, there will be no reaction as there would be an opposing signal.
ELECTRO-PNEUMATIC CIRCUITS FOR SINGLE ACTUATORS

Indirect Control of a Double Acting Cylinder (5/2 Valve, Double Solenoid)

ELECTRO-PNEUMATIC CIRCUITS FOR SINGLE ACTUATORS

Control of a Double Acting Cylinder, OR

Logic (Parallel Circuit)
 The piston of a double acting cylinder
travels out when either one of the two
push buttons is pressed.
 It returns when both are released.
 When push button PB1 or PB2 is pressed
coil Y1 is energised.
 The DCV switches over and the piston
travels to the final forward position.
 When both push buttons are released, the
signal is removed from Yl and the cylinder
travels back to its original position.
ELECTRO-PNEUMATIC CIRCUITS FOR SINGLE ACTUATORS

Control of a Double Acting Cylinder, AND Logic

 ELECTRO-HYDRAULICS
 Hydraulic systems are used wherever high power concentration, good heat dissipation or
extremely high forces are required.
 Electro-hydraulic systems are made up of hydraulic and electrical components:
 The movements and forces are generated by hydraulic means (e.g. by cylinders).
 Signal input and signal processing, on the other hand, are effected by electrical and
electronic components (e.g. electromechanical switching elements or stored-
program controls)
 ADVANTAGES OF ELECTRO-HYDRAULICS
The use of electrical and electronic components in the control of hydraulic systems is
advantageous for the following reasons:
 Electrical signals can be transmitted via cables quickly and easily and over great
distances. Mechanical signal transmission (linkages, cable-pulls) or hydraulic signal
transmission (tubes, pipes) are far more complex. This is the reason why electro-
hydraulic systems are being used increasingly frequently in aeroplanes, for example.
 In the field of automation, signal processing is generally effected by electrical means.
This enhances the options for the use of electro-hydraulic systems in automatic
production operations (e.g. in a fully automatic pressing line for the manufacture of car
wings).
 Many machines require complex control procedures (e.g. plastics processing). In such
cases, an electrical control is often less complex and more economical than a mechanical
or hydraulic control system.
FIELDS OF APPLICATION OF ELECTRO-HYDRAULICS
 Over the last 25 years, there has been rapid progress in the field of electrical control
technology.
 The use of electrical controls has opened up many new fields of application for
hydraulics
 Electro-hydraulics are used in a wide range of sectors, such as
 The machine construction sector (feed systems for machine tools, force generators
for presses and in the field of plastics processing)
 Automobile construction (drive systems for production machines)
 Aeroplane construction (landing flap operation, rudder operation)
 In shipbuilding (rudder operation)
 DESIGN OF AN ELECTRO-HYDRAULIC SYSTEM
 The following schematic diagram shows the two
principal subassemblies in an electro-hydraulic
system.
 Signal control section with signal input,
signal processing and control energy supply
 Hydraulic power section with power
supply section, power control section and
drive section
 An electrical signal is generated in the signal
control section, where it is processed and then
transmitted power section via the interface.
 In the power section, this electrical energy is
converted first into hydraulic and then
mechanical energy.
CIRCUIT SYMBOLS OF ELECTRO-HYDRAULIC SYSTEM