WHAT IS PNEUMATICS?

Pneumatic systems are widely used in machines, engines, and industrial applications. Air or gas is used in every pneumatic system to move an actuator, and can be as simple as an air-driven piston, or as complex as a mining operation with many actuators. In most cases, atmospheric air is used for compression; there is plenty of it, and it is free. Since pneumatic systems are quieter, cheaper to run, and easier to use, they are generally preferred over hydraulic systems in industry and manufacturing.

What Is Pneumatics?

Pneumatics refers to both the physical science of compressing air and to the branch of mechanical engineering that deals with compressed air or gas. Originally, pneumatics was as simple as taking a deep breath, compressing the air in your lungs, then blowing it out forcefully to ignite a fire or fire a dart from a tube. Pneumatics derives from the ancient Greek word for blowing, pneuma, and the same root form also appears in the English word pneumonia.

Common Parts Of A Pneumatic System

DRIVES/CYLINDERS

Using pneumatics, force is converted into potential energy, which is then converted into kinetic energy and used to drive actuators or cylinders. Typically, piston rods are used or other forms of actuation, such as 'rodless', are used for linear motions. Using either a single action or a double-action stroke, the piston rod produces an up-and-down or back-and-forth motion.

Single-acting pneumatic cylinders drive the piston rod linearly only in one direction. By expelling the compressed air, a vacuum is created, which allows the piston rod to return via a mechanical spring. By manipulating compressed air with valves, double-acting cylinders allow the load to move in a push-pull motion. As a result, the stroke length can be increased, as well as constant force can be maintained on alternating movements.

Several different types of rodless cylinders are available, including linear slides, magnetic couplings, inflatable bellows, and rotary vane pumps. In applications requiring long strokes or high-moment loads, they are usually located on a carriage alongside the piston.

VALVES

There are many functions that valves perform in pneumatics, including controlling and directing airflow. You can start up the system with a soft start or an on-off valve, and you can control the rate of airflow with flow control valves. Flow direction can be controlled by ball valves and angle seat valves, and a secondary system can be controlled by pilot valves.

Venting the system requires an exhaust valve. You'll need a shut-off valve to shut it down, and a safety dump valve to initiate an emergency stop. At specified intervals, these types of valves release air pressure from the system.

To direct or position the flow of air into the pneumatic system, simple air valves require some motivating force. When this force is applied directly to the operating medium, it is a direct-operated valve rather than a pilot or secondary valve. One of the simplest valves is the two-position flow control valve, which is either on or off.

The flow and directional control valves are self-explanatory, but some versions allow three-way directional control from the inlet to two outlets, and the more complex four-way valve. This allows the flow to be directed from the inlet to a choice of three outlet ports. Based on the flow rate or pressure of the inlet, proportional valves are electronically controlled using solenoids. Fluid pressures and flows must be distributed in varying ratios when using this type of valve with one or more outputs.

In modern pneumatics, solenoid valves are also increasingly common, and today's complex systems have given rise to universal valve terminals that enable modular valve configurations. So that many advanced and specific situations can be controlled simultaneously, the choice and use of valves have become quite a complicated undertaking.

FITTINGS

A pneumatic system consists of many components that need to be connected using fittings. Connecting the major system components with hoses, pipes, and tubes, pneumatic fittings conduct compressed air to the application's active components. Since the whole system operates under compressed gas or air pressure, all its components must fit together properly and be leak-proof.

The types and sizes of fittings vary, as well as the materials used, and the way they are connected. Even though other materials such as polymers are now being used, metal screw-in threads still provide the strongest bond. Using compression fittings, you can join pipes of different sizes or types, while barb fittings are most often used to join flexible tubing. There is a threaded end that connects to the pipe and a barbed cone that goes into the tube. For joining air hoses, many people prefer push-in fittings, which are often used in modern technology. Its quick connect-and-disconnect design makes it easy to change parts, and it comes in a variety of sizes and materials.

TUBING AND HOSES

There is a difference between tubing and hoses in a pneumatic system: hoses are typically used in high-pressure applications and are reinforced for extra strength; tubing, on the other hand, is used in low-pressure applications and does not require reinforcement. A flexible pneumatic hose or tubing is more widely used than a rigid one, and they are available in many different types. In pneumatic systems, flexible tubes and hoses are the most versatile components due to the development of strong polymers and application-specific materials. All you need to do is ensure that your hoses and tubing are the right size and type for your devices.

VACUUM TECHNOLOGY

In the presence of a vacuum, the air pressure is substantially below atmospheric pressure, specifically 300 bar or less. From rough vacuum to ultra-high vacuum, the available vacuum range can be divided into four categories. Vacuums are created by removing all the air from a contained space using a vacuum generator connected to your pneumatic system. A diffuser ejects compressed air forcibly, leaving a vacuum in the application. A suction pad or cup will be used to draw up the item on the workspace into the vacuum, where it will be gripped while being processed.

Modern industry and various manufacturing processes make use of vacuum technology, including food and beverage production, pharmaceuticals, metallurgy, and process engineering. Generally, they are used for delicate pick-and-place applications, such as plate glass and small electronic components, or for holding items in place. Probably the most well-known application of this technology is vacuum packaging.

AIR PREPARATION

Compressed air becomes hot, then cools again, producing condensation which contaminates the compressed air supply. Impurities such as dirt, dust, oil, and other particulates are also commonly found in atmospheric air. If compressed air containing such contaminants passes downstream into parts of the pneumatic system, such as cylinders, valves, and hoses, some damage is inevitably caused. The fittings and components along the compressor's outward journey to the application can contribute to further contamination, even if your compressor has filters, dryers, or regulators built in.

Your compressed air supply must be filtered to ensure that your system functions properly for as long as possible. A simple air filter can be installed for this purpose, but air pressure must still be monitored to ensure that the correct pressure is maintained. Furthermore, compressed air needs to be lubricated so that downstream equipment is not damaged by excessively dry air. Filtering, regulation, and lubrication can be handled by separate units, but it's more common to install a combined Filter-Regulator-Lubricator unit (FRL).

You should prepare the air at the point of use for your pneumatic system to ensure optimal performance. It is particularly important if the compressor is far away and there are opportunities for water and particulates to accumulate en route. In today's world, FRL units provide a comprehensive range of filtration options, operating pressure regulation, and lubrication options. Space-saving and cost-effective, they will extend the life of your pneumatic system if properly sized and installed.

SILENCERS

The purpose of pneumatic air silencers is to reduce excess noise when air is exhausted from your pneumatic system, similar to that of car exhaust silencers. When the exhaust air from a pneumatic system is vented, it often makes an explosive sound, depending on the force and pressure. Increasing the operational noise levels of the application as a whole can cause physical damage or disturbance to personnel. Adding a silencer to pneumatic cylinders, 5/2-way solenoid valves, or other associated devices is a cost-effective solution.

Furthermore, silencers can control the amount of airflow out of the unit with throttle valves that can be adjusted. In addition to controlling actuator speed, they also function similarly to needle valves. To protect the environment from harmful particulates, an exhaust cleaner may also be added to the silencer unit to clean the exhaust air.

Airmax Pneumatics is the leading air preparation unit manufacturer. India. We offer various types of industrial valves like pneumatic valves, pneumatic cylinders, and many more.