M A P P I N G OF SYLLABUS

WITH BOOKS

12
Sr. Topic Covered Related Books & Remark
No Page Nos
Unit-IV: Pneumatic Systems
1 Physical Components of a Pneumatic T1-153, T3-215, TT-
Systems 493
2 Air compressor T3-226
3 Air Receiver T3-227
4 Air Dryer T3-228
5 Air Service Treatment : T3-228
Air Filter T1-158
air regulator and Gauge,
Air Lubricator and Pressure regulation
Intake and Air Filter.
6 Introduction to Pneumatic Actuators T1-150, T3-244, R1-
249
7 Pneumatic Cylinders
8 Spring Actuator and Spring Actuator T1-160

with positioned
9 Case study of Robotic Pick and Place
robot

2
Books
Text Books
⚫ T1 W. Boltan ―Mechatronics: Electronic Control Systems in Mechanical
and Electrical Engineering‖ 6th Edition, Pearson Education, 2016
⚫ T2 David Alciatore and Maichael B Histand,―Introduction to
Mechatronics and Measurement Systems, 4th Edition,Tata McGraw Hill
2013
⚫ T3 K. P.Ramachandran,G. K.Vijayaraghavan and M. S.Balasundaram,
―Mechatronics-Integrated Mechanical Electronic Systems,Willey
Publication 2008

Reference Books
⚫ R1 Nitaigour P.Mahalik, Mechatronics-Principles, Concepts and
Applications,Tata McGraw Hill, Eleventh reprint 2011
⚫ R2 DevdasShetty and Richard A.Kolk, ―Mechatronics System Design,
Thomson India Edition 2007
⚫ R3 HMT Limited, ― Mechatronics,Tata McGraw-Hill Publishing House
4
Fluid Power
⚫ Fluid power is the energy transmitted and
controlled by means of a pressurized fluid,
either liquid or gas.The term fluid
power applies to both hydraulics and
pneumatics. Hydraulics (oil or water)
use liquids under pressure while
pneumatics use compressed air or other
neutral gases

 Example 2
5
 Pneumatics - Meaning
⚫ The English word pneumatic and its associate
noun pneumatics are derived from the Greek
“pneuma” meaning breath or air
⚫ Originally used to give a name to the
science of the motions and properties of
air
⚫ Compressed air is a vital utility- just like
water, gas and electricity used in
countless ways to benefit everyday life
⚫ Pneumatics is application of compressed
air (pressurized air) to power machine
or control or regulate machines
6
 Definition
⚫ Pneumatics may be defined as branch
of engineering science which deals
with the study of the behavior and
application of compressed air
⚫ Pneumatics can also be defined as the
branch of fluid power technology that
deals with generation, transmission
and control of power using
pressurized air

7
 General
⚫ Gas in a pneumatic system behaves like
a spring since it is compressible
⚫ Any gas can be used in pneumatic
system
⚫ But air is the most usual choice, for
obvious reasons
⚫ Exceptions are most likely to occur on
aircraft and space vehicles where an inert gas
such as nitrogen is preferred or the gas which
is generated on board is used
8
General
⚫ Pure nitrogen may be used if there is a
danger of combustion in a work
environment
⚫ In Pneumatic control, compressed air is
used as the working medium, normally at
a pressure from 6 bar to 8 bar
⚫ Using Pneumatic Control, maximum force
up to 50 kN can be developed

9
Choice of Working Medium and
System
⚫ The choice of medium depends on the
application. Some of the general, broad rules
followed in the selection of a working
medium are listed below:
⚫ When the system requirement is high
speed, medium pressure (usually 6 to 8
bar) and less accuracy of position,then
pneumatic system is preferred.
⚫ If the system requirement is high pressure
and high precision, a fluid system with
oil is good.
10
Choice of Working Medium and
System
⚫ When the power requirement is high
like in forging presses, sheet metal press,
it is impossible to use air system. Oil
hydraulics is the only choice
⚫ Air is used where quick response of
actuator is required
⚫ If temperate variation range in the
system is large, then use of air system
may run into condensation problems and
oil is preferred
11
Choice of Working Medium and
System
⚫ If the application requires only a medium
pressure and high positional accuracy is
required then hydro –pneumatic
system is preferred
⚫ Air is non-explosive, it is preferred where
fire/electric hazard are expected. Oil
systems are more prone to fire and
electrical hazards and are not
recommended in such applications.

12
Choice of Working Medium and
System….
⚫ Because air contains oxygen (about 20%)
and is not sufficient alone to provide
adequate lubrication of moving parts and
seals, oil is usually introduced into the air
stream near the actuator to provide this
lubrication preventing excessive wear and
oxidation

13
Efficiency
⚫ Practically,compressed air is a medium that
carries potential energy.
⚫ However it is expensive to produce
⚫ From energy efficiency point of view
compressed air may not appear
advantageous at first
⚫ Considering that it takes about 6 kW of
electrical energy to generate 0.75 kW
output on an air motor, compressed air has
an efficiency rating of only 12%
⚫ In spite of that compressed air is used due
to its other advantages:
14
Pneumatic System
⚫ Systems using gas for power transmission
are called pneumatic system
⚫ When air is compressed & stored, it can
be used as a medium for carrying out
mechanical work, measurement and for
controlling and operating equipment &
machines

15
Applications of pneumatics
Industrial applications
◦ Material handling
◦ Clamping
◦ Shifting
◦ Positioning
◦ Branching of material flow
◦ Packaging
◦ Filling
◦ Transfer of materials
◦ Sorting of parts
◦ Stamping and embossing of components

16
Applications of pneumatics
Pneumatic systems are used in carrying out
machining and some industrial
processes such as:
◦ Drilling
◦ Turning
◦ Milling
◦ Sawing
◦ Finishing
◦ Forming
17
S O M E OF TH E
PNEUMATI C
APPLICATIONS I N O U R
LIFE

18
A Pneumatic machine is used to
dismantle an automobile tire

19
A pneumatic machine is used in an
automobile painting

20
A heavy duty pneumatic jackhammer

21
A pneumatic filling machine

22
A dental drill is one of the uses of the
pneumatic technology

23
A pneumatic device is used to fill the
tire with compressed air to adjust the
tire pressure

24
Advantages and disadvantages
of pneumatics
Advantages:
⚫ Availability: Air is available everywhere in
unlimited quantity
⚫ Transport: Air can be easily transported
in pipelines, even over large distances
⚫ Storage: Compressed air can be stored in
a reservoir/tank and removed as required.

25
Advantages
⚫ Temperature:Compressed air is relatively
insensitive to temperature fluctuations
⚫ Cleanliness:Unlubricated exhaust air is
clean
⚫ The running cost is relatively inexpensive
⚫ Speed: Compressed air is a very fast
working medium. This enables high working
speeds to be attained
⚫ Overload safe: Pneumatic tools and
operating components can be loaded to the
point of stopping and are therefore overload
safe
26
Disadvantages
⚫ Preparation: Compressed air requires good
preparation. Dirt and condensates should be
removed
⚫ Speed: As air is compressible;it is difficult to
achieve uniform and constant piston speed
⚫ Force requirement: Compressed air is economical
only up to a certain force requirement. Under the
normal working pressure of 600 to 700 kPa (6 to 7
bar)
⚫ Noise level: The exhaust air is loud (noise).This
problem has now,however been largely solved due
to the development of sound absorption material
and silencers

27
Components of a Pneumatic System

28
Components of a Pneumatic System…
⚫ Air filters:
These are used to filter out the contaminants from the air.
⚫ Compressor:
Compressed air is generated by using air compressors. Air
compressors are either diesel or electrically operated. Based on
the requirement of compressed air, suitable capacity compressors
may be used.
⚫ Air cooler:
During compression operation, air temperature increases.
Therefore coolers are used to reduce the temperature of the
compressed air.
⚫ Dryer:
The water vapor or moisture in the air is separated from the air by
using a dryer.
29
Components of a Pneumatic System…
⚫ Control Valves:
Control valves are used to regulate, control and monitor for
control of direction flow,pressure etc.
⚫ Air Actuator:
Air cylindersand motors are used to obtain the required
movements of mechanical elements of pneumatic system.
⚫ Electric Motor:
Transforms electricalenergy into mechanicalenergy.It is
used to drive the compressor.
⚫ Receiver tank:
The compressed air coming from the compressor is stored
in the air receiver.

30
Receiver Tank (Reservoir)

Symbol

31
Receiver tank

32
Receiver tank
⚫ The air is compressed slowly in the compressor. But since
the pneumatic system needs continuous supply of air, this
compressed air has to be stored. The compressed air is
stored in an air receiver.
⚫ The air receiver smoothens the pulsating flow from the
compressor. It also helps the air to cool and condense the
moisture present.
⚫ The air receiver should be large enough to hold all the air
delivered by the compressor.
⚫ The pressure in the receiver is held higher than the system
operating pressure to compensate pressure loss in the pipes.
Also the large surface area of the receiver helps in dissipating
the heat from the compressed air.

33
Receiver tank

⚫ Generally the size of receiver depends on,

◦ Delivery volume of compressor.
◦ Air consumption.
◦ Pipeline network
◦ Type and nature of on-off regulation
◦ Permissible pressure difference in the pipelines

34
Compressor

Symbol

35
Compressor
⚫ Itis a mechanical device which converts
mechanical energy into fluid energy.
⚫ The compressor increases the air
pressure by reducing its volume which
also increases the temperature of the
compressed air.
⚫ The compressor is selected based on the
pressure it needs to operate and the
delivery volume.
36
Compressor
⚫ As a rule, pneumatic components are
designed for a maximum operating
pressure of 800-1000 kPa (8 - 10 bar) but
in practice it is recommended to operate
at between 500-600 kPa (5 and 6 bar) for
economic and safe use.
⚫ Due to the pressure losses in the
distribution system, the compressor
should be delivered between 650-700 kPa
(6.5 and 7) bar to attain these figures.
37
Classification of compressors
⚫ Positive displacement compressors
◦ piston type
🞄Single acting piston compressor
🞄Double acting piston compressor
🞄Multi-stage compressor
🞄Combined two stage compressors
◦ diaphragm type
◦ screw type
◦ vane compressor type
🞄Rotary vane compressor
🞄Liquid ring compressor
◦ Lobe compressor
⚫ Dynamic displacement compre Prosf.s
Dor. Dr. M. Chandwadkar 37
38
Positive displacement compressors:
Piston compressors
⚫ Single acting piston compressor

39
Positive displacement compressors:
Piston compressors
⚫ Double acting piston compressor

40
Positive displacement compressors:
Piston compressors
⚫ Multistage compressor

41
Positive displacement compressors:
Piston compressors
⚫ Combined two stage compressors

42
Positive displacement compressors:
Diaphragm compressor

43
Positive displacement compressors:
Screw compressor

44
Positive displacement compressors:
Vane compressor
⚫ Rotary vane compressors

45
Positive displacement compressors:
Vane compressor
⚫ Liquid ring compressor

46
Positive displacement compressors:
Lobe compressor

47
Dynamic compressor
Blower (Centrifugal type)

48
Air treatment
⚫ For satisfactory operation of the pneumatic system the
compressed air needs to be cleaned and dried.
⚫ Atmospheric air is contaminated with dust, smoke and
is humid.
⚫ These particles can cause wear of the system
components and presence of moisture may cause
corrosion.
⚫ Hence it is essential to treat the air to get rid of these
impurities.

49
Air treatment
⚫ The air treatment can be divided into three stages.

Stages of air treatment

50
Air treatment:
Filters
⚫ To prevent any damage to the compressor, the
contaminants present in the air need to be filtered out.
⚫ This is done by using inlet filters. These can be dry or
wet filters.
⚫ Dry filters use disposable cartridges. In the wet filter,
the incoming air is passed through an oil bath and then
through a fine wire mesh filter.
⚫ Dirt particles cling to the oil drops during bubbling and
are removed by wire mesh as they pass through it. In
the dry filter the cartridges are replaced during
servicing.
⚫ The wet filters are cleaned using detergent solution.

51
Air Filter
⚫ Symbol

52
Air treatment:
Cooler
⚫ As the air is compressed, the temperature of the air
increases. Therefore the air needs to be cooled. This is
done by using a cooler.It is a type of heat exchanger.
⚫ There are two types of coolers commonly employed
viz.air cooled and water cooled.
⚫ In the air cooled type, ambient air is used to cool the
high temperature compressed air, whereas in the water
cooled type,water is used as cooling medium.
⚫ These are counter flow type coolers where the cooling
medium flows in the direction opposite to the
compressed air. During cooling, the water vapor present
will condense which can be drained away later.

53
Air treatment:
⚫ Main line filter
These filters are used to remove the water vapors or
solid contaminants present in the pneumatic systems
main lines. These filters are discussed in detail as
follows.

⚫ Air filter and water trap

Air filter and water trap is used to
◦ prevent any solid contaminants from entering in the system.
◦ condense and remove water vapor that is present in the
compressed air.

54
Air treatment:
Air filter and water trap

55
Air treatment:
Refrigerated dryers

56
Air treatment:
⚫ Chemical dryers
When absolute dry air is needed chemical
dryers are used.
These dryers are of two types:
• adsorption dryer
• absorption dryer

57
Air treatment:
Chemical dryers
Adsorption dryer

58
Air treatment:
Chemical dryers
Absorption dryers

59
Air Dryer

Symbol
60
Air treatment:
Pressure regulation
⚫ In pneumatic systems, during high velocity compressed
air flow, there is flow-dependent pressure drop between
the receiver and load (application).
⚫ Therefore the pressure in the receiver is always kept
higher than the system pressure.
⚫ At the application site, the pressure is regulated to keep
it constant.
⚫ There are three ways to control the local pressure

61
Air treatment:
Pressure regulation
⚫ There are three ways to control the local pressure.
Types of pressure regulation

62
Air treatment:
Pressure regulation
⚫ Relief valve

63
Air treatment:
Pressure regulation
⚫ Non-relieving type pressure regulator

64
Pressure Regulator

⚫ Symbol

65
Air treatment:
Service units

⚫ During the preparation of compressed air, various

processes such as filtration, regulation and
lubrication are carried out by individual components.
The individual components are: separator/filter, pressure
regulator and lubricator.
⚫ Preparatory functions can be combined into one unit
which is called as ‘service unit’.

66
Air treatment:
Air Service units
Service Unit Components

Service Unit Symbol

67
Air Lubricator
⚫ Most moving parts require some type of
lubrication.The efficiency of cylinders, valves
and air motors can be greatly improved if
they are supplied with adequate lubrication.
⚫ Pneumatic components can be lubricated by
using an air line lubricator, a device for
adding lubricating oil in aerosol form into a
compressed air line.The air passing through
the lubricator transports the lubricant to air
tools, cylinders or other air operated
equipment
68
Air Lubricator
⚫ Symbol

69
Actuators
⚫ Actuators are output devices which convert energy
from pressurized hydraulic oil or compressed air into
the required type of action or motion.
⚫ In general, hydraulic or pneumatic systems are used for
gripping and/or moving operations in industry. These
operations are carried out by using actuators.

70
Actuators
Actuators can be classified into three types.
⚫ Linear actuators:
These devices convert hydraulic/pneumatic energy into linear
motion.
⚫ Rotary actuators:
These devices convert hydraulic/pneumaticenergy into rotary
motion.
⚫ Actuators to operate flow control valves:
These are used to control the flow and pressure of fluids such as
gases, steam or liquid.

⚫ The construction of hydraulic and pneumatic linear actuators is

similar. However they differ at their operating pressure ranges.
Typical pressure of hydraulic cylinders is about 100 bar and
of pneumatic system is around 10 bar.
71
Actuators:
Single acting cylinder

72
Actuators:
Double acting cylinder

Actuators
73
Actuators:
Cylinder end cushions

74
 Actuators:
Gear motor: a rotary actuator

Air Motor
75
Actuators:
Vane motor: a rotary actuator

76
Actuators:
Limited rotation actuators
Semi rotary vane type actuator

77
Videos
⚫ Hydraulic Gear Motor
⚫ Hydraulic Motor Overview

⚫ Types of Hydraulic Pumps

78
Actuators:
Speed control
⚫ For an actuator, the operational speed is determined by
the fluid flow rate and the cylinder actuator area or the
motor displacement.
⚫ The speed can only be controlled by adjusting the fluid
flow to the actuator, because the physical dimension of
the actuator is fixed.
⚫ Since the air is compressible, flow control is difficult as
compared to the hydraulic system.
⚫ There are various ways of controlling the fluid flow.

79
Actuators:
Speed control
Speed control by pump volume

80
Actuators:
Speed control
Speed control by pump volume
⚫ Consider a pump which delivers a fluid volume of ‘V’
per minute.The pump has a fixed displacement.
⚫ The volume of fluid goes either to the pump or to the
actuator.
⚫ When the direction control valve moves from its center
position the actuator of area ‘A’, the piston moves with
a velocity,
⚫ v =V /A
⚫ If the pump delivery volume ‘V’ can be adjusted by
altering swash plate angle of a piston pump or by using a
variable displacement vane pump, no further speed
control will be needed.

81
Case study of a pick-and-place robot

82
Case study of a pick-and-place robot
Pick-and-place

83
Case study of a pick-and-place robot
A gripper

84
Case study of a pick-and-place robot
⚫ The robot has 3 axes about which motion can occur:
◦ Rotation in a clockwise or anti-clockwise direction of the
unit on its base,
◦ Arm extension or contraction
◦ Arm up or down
◦ Also the gripper can open or close.
⚫ These movements can be actuated by the use of pneumatic
cylinders operated by solenoid-controlled valves with limit
switches to indicate when a motion is completed.

85
Case study of a pick-and-place robot
⚫ The clockwise rotation of the unit might result from the
piston in a cylinder being extended and the anti-clockwise
direction by its retraction.
⚫ Likewise the upward movement of the arm might result from
the piston in a linear cylinder being extended and the
downward motion from it retracting.
⚫ The extension of the arm by the piston in another cylinder
extending & its return movement by the piston retracting.
⚫ The gripper can be opened or closed by the piston in a linear
cylinder extending or retracting.

86
Case study of a pick-and-place robot
A typical program for such a robot might be:
1. Close an upright gripper on a component hanging
from an overhead feeder.
2. Contract the arm so that the component is withdrawn
from the feeder.
3. Rotate the arm in a horizontal plane so that it points
in the direction of the workpiece.
4. Extend the arm so that the gripper is over the
workpiece.
5. Rotate the wrist so that the component hangs
downwards from the gripper.

87
Case study of a pick-and-place robot
A typical program for such a robot might be:
6. Release the gripper so that the component falls into
the required position.
7. Rotate the gripper into an upright position.
8. Contract the arm.
9. Rotate the arm to point towards the feeder.

Repeat the sequence for the next component.

88
Case study of a pick-and-place robot
Robot
control

89
Case study of a pick-and-place robot
Closed-loop control for limb

90
 Comparison

Sr. No. Factors Hydraulic Pneumatic

1 Energy source Electrical /diesel Electrical /diesel
2 Running Needs cooler Runs cool
3 Space Compact Most compact
4 Transport Limited, basically Plant wide & easy
local
5 Energy cost Medium Highest
6 Availability Limited Unlimited

91
 Comparison...

Sr. No. Factors Hydraulic Pneumatic

7 Force of Very high force Medium force
application
8 Cleanliness Very clean Messy leaks
9 Speed of operation Low speed Accurate & high
of actuators speed
10 Safety Fire hazard Explosion proof
11 Noise level Less noisy Noisy
12 Temperature Insensitive Sensitive

92
ThankYou!

92