Karl-Erik Rydberg

Fluid and Mechatronic Systems

IEI, Linköping University

E-mail: karl-erik.rydberg@liu.se
Pneumatic systems - Contents
Ø Compressed air production system
Ø Thermo-dynamic equations
Ø Characteristic data and system efficiency
Ø Some applications and typical components
Ø Flow characteristics of pneumatic components
Ø Design of valve controlled actuator systems
Ø Pneumatic power and energy
Ø Example of improved system design
Ø Types of compressors and their characteristics
Ø Pneumatic sequence control system layout

Karl-Erik Rydberg 2
 Pneumatic systems -
Air production, distribution and users

Production Pneumatic systems

Distribution

Co mp - Reser-
res sor Co oler voir Shu t-off Service
valves units

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 Industrial air production system
Compressor stations, 15-935 kW, Atlas Copco

Pressure
switch

Motor
controller p2 Pressure
Cooling Filter pipe to
system system users

EM Compressor
nc Pressure
tank
Separation
Intake filter of water, oil
(p1 = 1 bar) and dust

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 Termo-dynamic equations for pneumatics
p = absolute gas press., [Pa]
V = gas volume [m3]

Ideal gas law: p ×V = m × R × T [ J ] m = gas mass, [kg]

R = gas const=287 [J/kg/K]
T = absolut gas temp, [K]

Polytropic exp.: p1 ×V1n = p2 ×V2n n = polytropic exponent, [-]

1/ k
Isentropic process (lossfree æ p ö
V2 = V1 × çç 1 ÷÷
adiabatic process): è p2 ø
n=k=1,4: k -1
æ p2 ö k
Temperature exp.: T2 = T1 × çç ÷÷
è p1 ø
Cooling effects reduces the polytropic exp. n = 1,25 common value.

Normal air stage, NTP: T0 = 293 K and p0 = 1,0 bar (100 kPa)

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 Pneumatic versus hydraulic
Characteristic data

"n = 1, 4 %
βp = n ⋅ p = $ ' bh ≈ 1500 MPa
Bulk modulus: # p = 1, 0MPa&
= 1,4 MPa

Dynamic viscosity:
(20 oC, 1 bar) hp = 1,85.10-5 Ns/m2 hh = 0,03 – 0,06 Ns/m2

Sound velocity: a p = κ ⋅ R⋅T = 343 m/s ah = βh / δ =1300 m/s

Pressure levels
Industrial standard: Pmax = 1,0 Mpa Pmax = 35 Mpa
Mobile standard: Pmax = 2,0 MPa Pmax = 45 MPa
Special applications: Pmax = 42 MPa Pmax = 300 MPa

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Thermal efficiency of a pneumatic system

he/c = Wt,full-pres expan / Wt,isentropic comp T3 = T1

n = 1,01 (isothermal compression)

n = 1,4 n = 1,25

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Overall system efficiency - Adiabatic
compression and full pressure expansion

El-motor efficiency: hem = 0,92,

Mechanical system efficiency: hm,s = 0,80,
Volumetric eff. single-stage piston comp: hv,c

n = 1,25

T3 = T1
n = 1,4

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Exemples of pneumatic applications
Festo – mobile pneumatics

Festo – industrial automation

Pneumatic robot: Festo–

Robotino (You Tube)

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 Pneumatic actuators
Pneumatic cylinder with control Rodless cylinder
valve, end cushioning and end
position transducers (ISO-standard)

Short stroke
cylinder

Motors with mechanical gearing Pneumatic muscle

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 Pneumatic valves

Pressure control with pressure

reducing valve

Flow control (velocity control) with

an orifice

El-controlled valves
Valve block
Damper for
return air

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 Vacuum-technology
Vacuum lifter Ejector-unit
(Bosch Rexroth)

Ejector

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Valve controlled pneumatic systems
Component characteristics: b- and C-values
T1 p1 p2

Component
under test
b, C
Flow
Up stream meter Down stream
pressure pressure
control valve control valve

ì1 for p2 / p1 £ b

q = C × p1 × w × Kt ï
w=í æ p2 / p1 - b ö
ï 1- ç ÷
2

for 1 ³ p2 / p1 > b
î è 1 - b ø

Pneumatic conductance: C, [litre/(s·bar)], (NTP)

Temperature correction: Kt = T0 / T1 , T0 = 293 K
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 Flow characteristics for components

w= 1 q = C ⋅ p1 ⋅ ω q
b, C

)(
C.p1
p1 = constant p1 p2
Volume flow, q (NTP)

Kt = 1.0

Sonic Subsonic
flow flow
b < p2/p1 <= 1
w= 0
0 b Pressure ratio, p2/p1 1.0
(p2=p1)

Critical pressure ratio, b: 0 ≤ b ≤ 0,528

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Serial connection of pneumatic
components

Find bs, Cs - simplified equations gives:

1 n
1 1 - bi
n

3
=å 3 bs = 1 - C å 2
2
s
Cs i =1 Ci i =1 Ci

q = Cs × p1 × ws × Kt (NTP)
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 Valve controlled cylinder – Pressure and
velocity characteristics
Max piston velocity:

Output flow:
Max piston velocity:
Valve flow: q2 = C2 × p2 × w2
C 2 × pa pa
p2 vmax = w2 = 1,0 ; £ b2
Cylinder flow: q2 = A2 × v × A2 p2
pa
pa = 100 kPa = 1,0 bar
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Valve controlled cylinder – Reduced piston velocity

Cyl. A a0 a1 The valve orifices passed by the

A1
A cylinder return flow (outlet orifices)
2 v- v+
p1
determine max piston velocity for
p2 both direction of motions.
)( C3, b3 Assume that the pneumatic
conductance of the orifices are equal:
C1 = C2 = C3 = C
C1, b1 )( )(
For positive stroking there are two series
connected orifices, (C2, C3), which gives:
C2, b2
+ C23 × pa C × pa
v = = 1/ 3
2 × A2
max
Displacement/Time-diagram A2
1
Cyl. Negative stroking with the outlet orifice
conductance C1 = C, gives:
A
0
C1 × pa C × pa + -
-
vmax = = ! vmax < vmax
A1 A1
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Time delay of pneumatic signals

A
A1 2 v- v+
p1
p2

Time delay unit

Volume
pv pc

)(
Time delay adj.

Volume pressure (pv) versus command pressure (pc)

p,p pc
c v

pv

1 bar
0 Time
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 Cylinder forces

A2 F
A1
F
p1 p2 pa
p2 pa
)( p2 = pa

A2
)( )(
A1 p1
ps pa

A1 × p1 - A2 × p2 - ( A1 - A2 )× pa = F A1 × p1 - A1 × pa = F

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 Pneumatic power
•
m m1 •
Ideal gas: p ×V = m × R × T V= p1 × = m1 × R × T1
r r1
Gas const. R = 287 J/(kg K)

•
m1 p1
”Normal” power: PN = × R × T1 = q1 ×
r0 r1
p0
Constant temp., T1 = T0 = 293 K, gives the power: PN = q N ×
r0
qN = normal flow, [m3/s] (NTP)
p0 = 1,0 bar and
r0 = 1,23 kg/m3

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 Pneumatic energy

Energy = Power *time, [Ws, Nm, J]

Totala actuator energy: EPA = åP N , PA × Dt PA

Energy consumption for pneumatic cylinder:

p
EPA = ps × Vtot = ps × d p2 × BL × n
4
dp = piston diameter, [m], ps = supply pressure [Pa],
BL = displacement lenght, [m], n = number of strokes [-]

Compressor energy: EK = EPA / htot

htot = overall system efficiency
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 Application –
Pneumatic control of a saw bar
End position cushioning
Adjustable orifice

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 Faster cycle with two pressure system
7,5
Single pressure system

5
Velocity 1m/s=4V

Voltage (V)
5 4
Pin (1 bar=0,5V)
2 1
1
3 2

2,5

Pout
0
0 0,2 0,4 0,6 0,8 1 1,2
2 1

Time (s)

Two pressure system 7,5

Velocity (1m/s=4V)
Pout
5
Voltage (V)

Pin (1 bar=0,5V)

2,5

0
0 0,2 0,4 0,6 0,8 1 1,2
Time (s)

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Two-stage piston compressor with inter-cooler

Two compressor stages

Piston
rod Inter-
cooler
Centrifugal
unloader Overhung
crankshaft
Splash
Oil level lubrication
indicator

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Screw compressor, Atlas Copco

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Portable compressor units, Atlas Copco
Atlas Copco is the
in the portable co
Horsepower
designing our uni
strongest, most fu
880 Hp on th
compressors
have created a com
application - from
construction indu
oil and gas busine
front runner in pro
smallest product l
440 Hp
are becoming an i
in today’s industry
Health, Safety
Atlas Copco’s stri
follow ISO 9001
All
30components
Hp a
exacting standard
the most demandi
Karl-Erik Rydberg 26
 Volumetric efficiency for piston compressor

0,71

Multi-step compression - equal pressure ratio for n steps:

p2 p
= ... = n +1 ; p1 = 1 bar, pn+1 = final pressure
p1 pn
n Volumetric efficiency for n steps:
é p2 ù
2
é3ù
ê ú = pn+1 [bar] ; Ex : ê ú = 9 [bar] hvtot = hv1 ×hv 2 × ... ×hvn
ë p1 û ë1 û
Karl-Erik Rydberg 27
High pressure compressors, 350 – 420 bar, 3-4 -steps
piston compressors, (J.A. Becker, Bauer)

J.A. Becker
Pressure ratio 3 steps:
p2 p3 p4
= = ; p4 = final pressure
p1 p2 p3
3
é p2 ù Pr essure - ratio
ê ú = 350bar Þ = 7,05
ë p1 û step

Overall efficiency:
elmotor-compressor

p = 80 bar: htot ≈ 0,10

p = 350 bar: htot ≈ 0,065

Karl-Erik Rydberg 28
 Flow/pressure characteristics for
different compressor types
Displacement compressor
Outlet with low volumetric
pressure efficiency
[bar]

20 Displacement
compressor with
high volumetric
15 “Turbo”-compressor efficiency

10

1
0 Normal flow [m3/h]
Karl-Erik Rydberg 29
 Pneumatic sequence control

Displacement/time-
diagram for sequence
control of 3 cylinders,
A, B and C.

Group I Group II
Symbol-
circuit
according
to the
Cascade-
method.
All end
position
signals (a0, a1,
b0, b1, c0, c1)
must be used.

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Distributed
pneumatic
system,
Interact,
Hoerbiger-
Origa

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 Energy efficient pneumatic system
Closed pneumatic system
Possible(New(
Air consumption is reduced by letting
High
theTechnology(
Pressure Low
Pressure return air from positive cylinder
stroke goes to a low pressure tank. This
air is then used for negative stroke.
3/2 Valve
X-Block
High
Pressure Low
Pressure

X-Block
3/2 Valve

POWER STROKE

Source: Hank van Ormer, Air Power, USA

27
RETURN STROKE
32