Pneumatic Automation in Industrial Applications
OBJECTIVE:
The objective of this assignment is to understand the concept of pneumatic automation and its role in
industrial applications. This assignment aims to study the working principle of
pneumatic systems, the function of basic pneumatic components, and the use of
compressed air for automation. It also focuses on understanding how pneumatic
automation is applied in industries for operations such as material handling,
packaging, assembly, sorting, and safety systems, in order to improve
productivity, efficiency, and operational safety.
WORKING PRINCIPLE OF PNEUMATIC SYSTEMS:
The working principle of a pneumatic system is based on
the compression and controlled release of air.
Atmospheric air is first compressed using an air compressor and stored
at high pressure. This compressed air is then passed through
control devices like valves, which decide
when, where, and how much air should flow. When air enters a pneumatic actuator
such as a cylinder, it pushes the piston
and creates linear motion.
When the air is released or
redirected, the piston returns to its original position. This simple principle
is used to perform various industrial tasks like pushing, pulling, lifting, and
positioning.
A pneumatic automation system consists of several important components that work together smoothly. The
air compressor is the heart of the system, as it compresses atmospheric air and
supplies it to the system. The FRL unit
(Filter, Regulator, Lubricator) cleans the air, controls pressure and
lubricates components to ensure smooth operation. Directional control valves
control the direction of air flow and decide the movement of cylinders.
Pneumatic cylinders convert air pressure
into mechanical motion.
Air pipes and fittings carry
compressed air safely between different components.
Each component has a specific
role, and the system works
efficiently only when all components function properly.
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ROLE OF COMPRESSED AIR IN INDUSTRIAL AUTOMATION:
Compressed air acts as the power source
in pneumatic automation. It stores energy in the form
of pressure and releases it when required to perform work. Compressed air is
preferred in industries because it is non-flammable, clean, and safe,
especially in hazardous environments. It allows fast operation, easy control, and quick
stopping of machines. Due to these qualities, compressed air plays a very
important role in industrial automation systems where safety and speed are
critical.
INDUSTRIAL APPLICATION:
USE OF PNEUMATIC AUTOMATION IN MANUFACTURING
INDUSTRIES:
In manufacturing industries, pneumatic automation is
used for operations like clamping, pressing, drilling, and material handling.
Pneumatic cylinders help hold work pieces firmly during machining processes.
Automated pneumatic systems increase production speed and reduce dependency on
manual labour. They also improve accuracy and consistency in manufacturing
processes, which is essential for maintaining product quality.
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PNEUMATIC AUTOMATION IN PACKAGING AND MATERIAL HANDLING:
Packaging industries rely heavily on pneumatic
automation for tasks such as filling, sealing, labelling, cutting, and sorting.
Pneumatic actuators move products quickly and accurately on conveyors. In material handling, pneumatic systems are used to push, lift, divert, and position products. These systems
allow smooth and continuous flow of materials, making packaging operations
faster and more efficient.
APPLICATION OF PNEUMATIC SYSTEMS IN ASSEMBLY LINES:
In assembly lines, pneumatic automation is used for
component positioning, fastening, and transferring parts from one station to
another. Pneumatic systems ensure synchronized and sequential operations, which
are essential for smooth assembly processes.
Their fast response and repeatability help maintain production speed and
reduce assembly errors.
PNEUMATIC AUTOMATION IN FOOD AND BEVERAGE INDUSTRIES:
Food and beverage industries prefer pneumatic automation
because it is clean and hygienic. Pneumatic
systems are used in bottle
filling, capping, sorting,
and packaging processes. Since air does not contaminate food products, pneumatic automation is ideal
for industries that follow
strict hygiene standards. It also allows easy cleaning and maintenance of
machines.
Etc.…...
Example:
Working of the Pneumatic
Circuit:
In this pneumatic circuit, two double-acting cylinders
(A and B) are used. Each cylinder is controlled by a 5/2 directional control
valve. The circuit
also includes two OR (shuttle) valves and three normally closed (NC) push button valves named
Good, Rework, and Reject.
When the Good push button is pressed,
compressed air flows through the good push button and then
splits into two paths. One path goes to the first OR valve, and the second path goes to the second OR valve. The first OR valve supplies
air to the forward pilot side of the first
5/2 valve, causing cylinder
A to move forward. At the same time, the second OR valve supplies
air to the reverse pilot side of the second 5/2 valve, causing cylinder
B to move backward. As a result,
cylinder A is in the forward position and cylinder B is in the backward
position.
When the Rework push button is pressed, compressed air
flows through the Rework push button and then divides into two separate paths.
One path goes to the first OR valve, and the other path goes directly
to the forward pilot side of the second 5/2 valve. The OR valve blocks
the signal coming from the good push button and allows the Rework signal to
pass. The first OR valve sends air to the forward
pilot side of the first 5/2 valve,
and the second
5/2 valve also receives air on its forward side. As a result, both cylinder A and cylinder
B move to the forward position.
When the Reject push button is pressed, compressed air
flows through the Reject push button and again splits into two paths. One path
goes directly to the reverse pilot side of the first 5/2 valve, and the second
path goes to the second OR valve. The
OR valve blocks the Good push button path and allows the Reject signal to pass.
The second OR valve then sends air to the reverse pilot side of the second 5/2
valve. As a result, both cylinder A and
cylinder B move to the backward position.
Conclusion:
This pneumatic circuit demonstrates an effective sorting
system using two cylinders, directional control valves, and pneumatic logic. By
operating different push buttons, the cylinders move in specific combinations
to achieve Good, Rework, and Reject positions.
The use of OR valves allow flexible and independent operation without
signal interference. Such pneumatic automation systems improve accuracy,
reliability, and efficiency in industrial applications.