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Design and Simulation of Electro-Pneumatic Sequential System Using Fluid Sim Software

Ahammed

1234Graduate Student, 5Assistant Professor Department of Mechanical Engineering, AWH Engineering College Calicut, Kerala, India

Abstract – Electro-pneumatic control system is an integration of pneumatics and electrical technology. The control of pneumatic components by electrical impulses is known as electro-pneumatics. Electro-pneumatic commonly used in low-cost industrial applications. Electro-Pneumatic system consist of electrical control system operating pneumatic power system. In electro-pneumatic system solenoidvalveareusedastheinterfacebetweenelectricaland pneumatic system. Control of Electro-pneumatic system is achievedusingeitheracombinationofrelayandcontactorsor PLC.In this work consist design and simulation of pneumatic cascade A+B+B-A- sequential circuit using FluidSim -P Software.

Key Words: Electro-Pneumatic Sytem, Simulation, PLC, Relay.

1.INTRODUCTION

Variousautomationtechniqueplaysakeyroleinenhancing overallindustrialproductivity.Fluidpowerhasuniquerole in industrial automation. Pneumatic based on fluid power principle.

Pneumatic is the study of system operated by air under pressure.“Pneuma”isaGreekwordwhichmeans“Breath”. Air taken from the atmosphere is compressed in a compressor, and this compressed air is used to produce necessaryworkoutput.Electro-pneumaticcircuitsareone of the industrial automation cornerstones. Programmable LogicControllers(PLC)areoneofthemaincomponentsof thesecircuits.Electro-pneumaticcircuitarecommonlyused forlow-cost industrial automations.In electro -pneumatic system pneumatic power system operated by electrical control system. Solenoid valve act as interface between electricalandpneumaticsystem.

FluidSIMisasoftwaretoolforcreatingsimulatinghydraulic, pneumatic, electro-hydraulic electro-pneumatic digital electronic system. FESTO FluidSim software is used for simulationofpneumaticpowersystem

Main aim of work is design simulate electro-pneumatic cascade sequential circuit A+B+B-A-configuration, using variouselectricalandpneumaticcomponents.

2. ELECTRO-PNEUMATICS SYSTEM

Inapneumaticsystemcompressoristheonlydevicewhich consumes electricity. In industry electro -pneumatic have wide applications. In electro-pneumatic circuit solenoidoperatedvalves,starter/pushbuttons,make/breakswitches working using electricity. Generally, in pneumatics, air movesthespoolbutinElectro-pneumaticsinsteadofusing airtomovethespoolofdirectioncontrolValveapplyvoltage toasolenoidcoil.Thisvoltagewillgenerateanelectromotive force,resultingintheshiftingofspool

Pneumatic system generally consists pneumatic signal controlsectionandpneumaticpowersection.Mechanically operated push button is commonly used as signal input elements.Pneumaticsignalisgettingprocessedusingsignal processing unit. Signal output execute extension or retractionofcylinderorclockwiseoranticlockwisemotion ofrotoractuator.Flowcontrolelementsactasaninterface between pneumatic signal control section and pneumatic powersections.

Fig1:PneumaticSystemControl

Electro-pneumaticsystemconsists Electricalsignalcontrol sectionandpneumaticpowersection.

Muhammed Ishack V1 ,

Adil P2 , Amal P K3 , Rohith V T4 Jibi R5

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Electro-pneumaticcontrolsinvolvethreeimportantsteps

Signal generation using input devices: Signalisgenerating usingdevicessuchasswitches,contactors,sensors.

Processing of signals: Signals are processed using contactors and relays, or programmable logic controllers (PLC).

Signal Output: Outputfromsignalprocessingunitsareused to activate output devices like solenoids, indicators or audiblealarms.

2:Electro-PneumaticSystemControl

Inoperationofelectro-pneumaticcontrollersystem,electropneumaticcontrolsystemisnotshowninasingleoverall circuit diagram, but in two separate diagram one for electricalpartandoneforpneumaticpart.

Componentsofelectricalsignalcontrol

Sevenelectricaldevicesarecommonlyusedinthecontrol of fluidpowersystem

Manuallyactuatedpushbuttonswitches

Limitswitches

Pressureswitches

Solenoids

Relay

Timers

Temperatureswitches

Otherdevicesalsousedinelectro-pneumaticare

Proximitysensor

Electriccounter

Manually actuated push button switches: Pushbuttonis usedtoopenorcloseelectriccontrolcircuit.Theyareused toapplycurrenttoaloadorinterruptacircuit.Pushbutton isdistinguishedaccordingtocontactbehavior.

Normally open: In the case of normally open contact the circuit is open if the switch is in its initial position (not actuated)Thecircuitisclosedbypressingthepushbutton

currentflowstotheload,whentheplungerisreleased,the springreturntheswitchtoitsinitialposition,interrupting thecircuit.

Normallyclosed:Inthiscasethecircuitisclosedwhenthe switchisinitsinitialposition.Thecircuitisinterruptedby pressingthepushbutton

Change-over:Changeovercontactcombinesthefunctions of the normally open and normally closed contact in one device Changeovercontactsareusedtocloseonecircuit andopenanotherinoneswitchingoperationcircuitsare momentarilyinterruptedduringchangeover

Normallyopen NormallyClosed Change-Over

Fig3:Manuallyactuatedpushbuttonswitchessymbol

Limit switches: Limitswitchesactivatedbythepositionof a fluidpowercomponent. Theactuationoflimitswitch provides an electrical signal that causes an appropriate systemresponse.

Limitswitchesareclassifiedbymethodofactuationlever actuatedandspringactuated. 1

Fig4:Limitswitchsymbol

Pressure switches: Pressureswitchesarebasicallyelectropneumatic signal converter, and opens or closes an electrical switch when a pre-determined pressure is reached. Bellows or diaphragm are used to sense the changeofpressureandexpandorcontractinresponse.

Fig5:Pressureswitchsymbol

Solenoids: Electrically actuated direction control valves form the interface between the two parts of an electropneumaticcontrol.Mainobjectiveofelectricallyactuated DCVs include controlling air supply and extending and retractingcylinderdrives.TheDCVsarecontrolledwiththe aid of solenoids can be divided in to two group spring returnvalvewhichremainactuatedaslongascurrentflow through the solenoid. Double solenoid valves which maintainthelastswitchedpositionevenwhennocurrent flowsthroughthesolenoid.

Fig

International

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zero.Foreachelectricalpulseinputtothecoil,thecounter value incremented by one. Down counter counts down electricalsignalsfrompresetvalue.

Fig6:5/2-waydoublesolenoidvalve

Relay: A relay is an electromagnetically actuated switch. Whenvoltageisappliedtosolenoidcoil,anelectromagnet fieldresult.Thiscausesthearmaturetoattractedtothecoil core. The armature actuates the relay contacts either openingorclosingthem,dependingonthedesign.Areturn spring restore the armature to its initial position when currenttothecoilisinterrupted.

Fig10:RelayCounter

Identification of components

Thecomponentsinthecircuitdiagramofacontrolsystem areidentifiedbyaletterinaccordancewithfollowingtable. Componentswithidenticalidentifyinglettersareassigned consecutivenumbers.

7:Relay

Time delay relays: Timersarerequiredincontrolsystemto introduce time delays between work operations via the associated control elements. Electronic timers are most commonlyused.Therearetwotypesoftimedelayon-delay timerandoff-delaytimer.

Fig8:Timedelayrelay

Temperature Switch: Temperature switch automatically senses a change in temperature and open or closes an electrical switch when a predetermined temperature is reached.Itcanbeeithernormallyopenorclosed.

Proximity sensors: Commonly using proximity sensor in pneumaticcircuitasshownbelow.

Fig9:ProximitySensor

Electronic Counters: Electroniccountersareusedtocount thenoofsignalspassingthroughit.Therearetwotypesof countersupcountercountselectricalsignalsupwardsfrom

Table1:IdentificationLetterofComponents

3.WORKDONE

Inanelectro-pneumaticsequencecircuitusuallyhavetwoor more cylinder that extend or retract in pre-defined sequence.Inordertoavoidsignalconflictcascademethodis used.

RequiredSequencemotionA+B+B-A-

Fig11:PositionalLayoutwithNotation

Fig

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FlowChartforElectro-PneumaticCircuitDesign

12:FlowChart-Electro-PneumaticCircuitDesign

AsequentialcircuitisdesignedwithA+B+B-A-motion.Total twodoubleactingcylindersareused.Eachonerespectively designed and dedicated to the sequential operation in system.Eachcylinderactivateswithtwospecificproximity sensorsforthemotionfunction.

Fluid Sim Pneumatic simulation software is used for simulating pneumatic circuit. Fluid Sim Pneumatics is a teaching tool for simulating pneumatics basics and runs using Microsoft Windows. The Fluid Sim Pneumatic Simulation software supports learning, educating, and visualizing pneumatic knowledge. The Pneumatic componentswhichareexplainedwithtextualdescriptions, figures,animationsanditsworkingprinciples.Theuserwill quicklylearntodrawandsimulate electro-pneumaticcircuitdiagram.

Methods to Control Double Acting Cylinder

Case 1:Theelectro-pneumaticdiagramgivenbelowshowsa simple A+A- circuit. As the piston is in A0 it is in on condition.WheneverA0sensoronelectriccurrentflowfrom 24Vto 0V, then left position of valve KA+ will get active compressedairwillgotoleftsideofpneumaticcylinderand pistonwillmoveforward.Whenpistoncompletelyoutward A1 close KA- get electricity right side will become active compressed air go to right side of cylinder piston moves backwarddirection.

Fig

Fig13:SimpleA+A-Circuit.

Fig14:StartingofExtension

Fig15:StartingofRetraction

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. Fig16:DuringRetraction

Theabovecircuitpistonwillmoveforwardandbackward continuouslywiththehelpofsensors.

Case 2: whenpushbuttonpressedcylindermovesinforward directionandreleasingpushbuttonshouldmovebackward direction.

Case 3: Push button can be replaced by switchpiston will move forward and stay there, when the switch is again pressed the cylinderretracted.

Fig17:A+A-PushButtonRelayCircuit

Fig18:A+A-PushButtonRelayCircuit:Extension

Fig19:A+A-PushButtonRelayCircuit:Retraction

Fig20:A+A-SwitchRelayCircuit

Fig21:A+A-SwitchRelayCircuit:Extension

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Case 4: Whenpressingswitchthepistonshouldmoveforwardand backwardautomaticallyuntilagainpressingswitch.

AssoonasswitchispushedrelaygotelectricityR0isclosed A0functionallyinitiallyclosedduetopistonisinretracted conditionKA+getelectricityleftsideofsolenoidvalvewill active.Socompressedairgotoleftsidecylinder,pistonhas start moving forward. As soon as piston moves a little bit forwardA0openKA+deactivated.Assoonaspistonreach A1 the circuit closed, KA- got electricity the right side of solenoidvalveactivatedcompressedairgoestorightsideof valvepistonretracted.Thiswillberetractedconditionuntil theswitchisagainpressed.

Case 5: Latchingcircuitmainlyconsistnormallyopenpush button,normallyclosedpushbutton,relaycoilandrelayNo switch.

Fig26:A+A-LatchingCircuit

Assoonasstartbuttonispushedelectricityflowingthrough start push button, electricity flowing through stop push button.Startbuttonisfunctionallyclosedandstopbuttonis normallyclosed.

As soon as electricity go through R0, R0 normally open switchwillclose.AssoonasR0closedelectricitygothrough startbuttonandelectricitygothroughR0.Evenafterpush buttondisengageselectricityisgoingthroughR0andreach relaynowsystemwill work automaticallytillpushbutton

Fig22:A+A-SwitchRelayCircuit:Retraction

Fig23:A+A-SwitchRelaySensorCircuit

Fig24:A+A-SwitchRelaySensorCircuitExtension

Fig25:A+A-SwitchRelaySensorCircuitRetraction

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pressed. When stop button pressed, R0 deactivated functionally closed of R0 converted in to normally open. Evenifstopbuttoncomebackthecircuitnotwork.

Fig27:A+A-LatchingCircuit:Extension

Fig28:A+A-LatchingCircuit:Retraction

Electro Pneumatic Circuit Diagram for The Proposed Design A+B+B-A-

Step 1:DrawthecylinderAandBwith5/2doublesolenoid directionalcontrolvalve.Connectcompressedpowersupply. Indicatethepositionofthelimitswitch.

Fig29:CylinderwithSolenoidValve figurebelowrepresentelectricalcircuitdiagramfor proposeddesign.

Fig30:ElectricalCircuitDiagram

Table 2 indicate a list of symbols that explains the cycle movement

Symbol

Detail

KA+ SolenoidforforwardmotionofcylinderA

KA- SolenoidforbackwardmotionofcylinderA

KB+ SolenoidforforwardmotionofcylinderB

KB- SolenoidforbackwardmotionofcylinderB

R1 Relayforgroupone

R2 Relayforgrouptwo

SensorindicatesCylinderAcompletely retractedposition.

SensorindicatesCylinderAcompletely extendedposition.

B0 SensorindicatesCylinderBcompletely retractedposition.

B1 SensorindicatesCylinderBcompletely retractedposition.

SRT Startpushbutton

STP Stoppushbutton

Table2:SymbolusedandTheirDetails

Electro-pneumaticcircuitconsisttwo-partpneumaticpart and electro part. Pneumatic part of circuit consists two doubleactingcylinder,two5/2doublesolenoidvalveand sourceofcompressedair.Electropneumaticcascadecircuit consist two group R1 and R2 are relay assigned to each group.RelayR1usedforA+B+movementandRelayR2used forA-B- movement.Grouponeisactive whenrelayone is activeandgrouptwoisactiverelaytwoisactive. Thereare foursensorsareusedA0,A1,B0,B1.A0tellsincylinderA piston completely in retracted position, A1tells piston completelyinextendedposition.B0tellsincylinderBpiston completelyinretractedposition,B1tellspistoncompletelyin extended position. For A+ motion R1 should be active B0 sensorshouldsense.WhenKA+getactivatedA+motionget activated. For B+ motion R1, A1should be active. KB+ get

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activatedB+motionhappens.ForB-totakeplaceR2should be active B1 sensor should be sensed. For A- motion R2 shouldbeactiveandB0sensorshouldbesensed.

Step 2:A+Movement

Step 4:B-Movement

Fig33:B-Movement

Step 4:A-Movement

Fig31:A+Movement

Step 3:B+Movement

Fig34:A-Movement

In the above circuit after A- motion completed the circuit stopped.Forcontinuousmotionanotherswitch(Normally open contactA0)Placedasshownbelow.

Fig32:B+Movement

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Designing Sequential Electro-Pneumatic System Using PLC Ladder Diagram

The PLC controls industrial machines and processes. In differentareasoftheindustry,PLCarebeingapplied.Inthe pastthemovementsofindustrialmachineswerecontrolled by relay circuits. These relay-controlled systems were replaced by PLC. The primary function of the PLC was to perform the sequential operations that were previously implementedwithrelays.

Ladder logic is a programming language that represents aprogram byagraphical diagram based onthe circuitdiagramsof relaylogichardware. Ladderdiagrams are used to describe the logic of electrical control system. Ladderdiagramsarespecializedschematicscommonlyused todocumentindustrialcontrollogicsystem.Theyarecalled “ladder”diagramsbecausetheyresemblealadder,withtwo vertical rails (supply power) and as many “rungs” (horizontallines)astherearecontrolcircuitstorepresent.

Fig35:ContinuousMotionCircuit

Fig36:LadderDiagram

Step 1: A+Movement

Fig37:A+Movement

Step 2: B+Movement

Fig38:B+Movement

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Step 3: B-Movement

Fig39:B-Movement

Step 4: A-Movement

Fig40:A-Movement

4.CONCLUSION

Nowadaysautomationisemployedineverysmallandlarge industry. Automated process has reduced human effort savedtimeandincreasedrateofprocesscompletion.Work in this article consists design and simulation of electropneumatic sequential circuit using Fluid Sim -Pneumatic software. Electric circuit are designed and sequence of operationaretestedbyusingFluidSim-PneumaticSoftware. Electrical ladder diagram easily converted in to a PLC programmingladderdiagramforabovesequential motion andsimulatedusingFluidSim-Pneumaticsoftware.

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[3] Adam Szcześniak, and Zbigniew Szcześniak “Fast Designing Ladder Diagram of Programmable Logic Controller for a Technological Process” Intl Journal of ElectronicsandTelecommunications,2022,Vol.68,No. 4,Pp.709-714

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BIOGRAPHIES

Mr. Ahammed Adil P Final YearB-tech student in the Mechanical Engineering DepartmentatAWHEngineeringCollege CalicutKeralaIndia.

Mr.Jibi.R CurrentlyworkingasanAssistant Professor in the mechanical engineering department at AWH Engineering College Calicut Kerala India. He has published 13 International journals and presented two articlesininternationalconference.Hehas morethan11yearsexperienceinteaching andone-yearIndustrialexperienceinPress toolandMoldmaking.Hisinterestedareais computer aided design and analysis, Production Technology and Industrial hydraulicsandpneumatics

Mr Muhammed Ishack V FinalYearBtech student in the Mechanical Engineering Department at AWH EngineeringCollegeCalicutKeralaIndia

Mr. Rohith VT FinalYearB-techstudent in the Mechanical Engineering DepartmentatAWHEngineeringCollege CalicutKeralaIndia

Mr. Amal P K FinalYearB-techstudentin the Mechanical Engineering Department at AWH Engineering College Calicut KeralaIndia

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