10+ Components of Pneumatic System You Need to Know

January 06, 2024
Komponen sistem pneumatik dan fungsinya

Pneumatic systems are widely used in various industries such as manufacturing, automotive, agriculture, and construction. These systems utilize compressed air as a medium to move and control mechanical devices. 

Pneumatic systems offer power, control, durability, efficiency, and safety advantages. Therefore, understanding how a pneumatic system works and the components involved is essential to optimizing its use. 

By learning about the basic principles of pneumatics and the functions of each component, you can operate the system effectively and plan its implementation in your company. This will help you avoid errors in component selection that could lead to suboptimal performance. 

In this article, the Bawalaksana team will explore the different components of a pneumatic system and provide a guide for choosing the right components for your company.

The pneumatic system has several components that work together to create mechanical motion. Here are the equipment needed for a pneumatic system:

Air Compressor

Air compressors are the primary provider of compressed air in pneumatic systems. This device enables the collection and compression of air from the surrounding environment, resulting in pressurized air, which is stored in the Air Reservoir Tank.

When selecting an Air Compressor for a pneumatic system, it is essential to take into account the following factors:

  • Select the appropriate type of Air Compressor for your company’s specific application. Consider whether you need a stationary or portable compressor, as well as whether it should be piston, screw, or centrifugal. Additionally, consider whether you prefer an oil-injected or oil-free air compressor.
  • Choose an Air Compressor with the appropriate capacity, air pressure, and air quality for your application. It is crucial to consider the specific requirements of your application when selecting an Air Compressor. The air content in the Air Compressor may contain oil or water, so it is crucial to ensure that the compressor you choose can provide clean and dry air if necessary. By carefully evaluating your needs and considering factors such as capacity, air pressure, and air quality, you can make an informed decision and select the suitable Air Compressor for your application.
  • When selecting an Air Compressor, opting for one equipped with a VSD inverter or advanced technology is advisable. This will ensure the compressor has energy-saving capabilities, allowing for more efficient operation and reduced energy consumption.
  • It is crucial to prioritize air compressor products that offer comprehensive and readily available warranties. It is advisable to select a vendor with a strong reputation and extensive experience in the industry. Additionally, consider opting for a supplier that provides spare parts at a reasonable price.
Read Also: Basic Principles of Pneumatic Systems for Industrial Automation
Pneumatic Systems Diagram for Industrial - Komponen Sistem Pneumatik

Refrigerated Air Dryer

The next component in the system is the Refrigerated Air Dryer. Its primary purpose is to eliminate moisture from the air utilized in the pneumatic system. According to Pneumatech, the Refrigerated Air Dryer operates in the following manner:

  • Moisture Removal: Pressurized air exiting the compressor can contain contaminants such as moisture, dust, and oil residues. This moisture can damage the compressor, air motors, and valves and contaminate products. Refrigerated Air Dryers can eliminate this moisture and prevent any potential risks it may cause.
  • Preventing Condensation: A refrigerated air dryer is the best solution to avoid condensation when the ambient temperature is less than 50°C/122°F.
  • Energy Savings: The Refrigerated Air Dryer has low initial costs, is easy to use and maintain, and can extend the overall life of pneumatic devices. This device also generally offers energy savings.

Air humidity can damage pneumatic components, including valves, cylinders, and other control devices. Therefore, Refrigerator-Air Dryers help preserve each pneumatic component’s durability and optimal performance by eliminating air humidity. 

To aid in selecting the most appropriate Refrigerated Air Dryer for your pneumatic system, we offer the following helpful guidelines:  

  • Determine the maximum air flow rate (CFM) required for your system. Then, check the maximum pressure and capacity of the air dryer you want to purchase to match the capacity of the Air Compressor you have.
  • Identify the pressure dew point (PDP) required for your application. Refrigerated Air Dryers can have a Pressure Dew Point (PDP) at a temperature of 3°C (37.4°F). Ensure that this criterion is suitable for the application needs of your company. 
  • Determine the maximum ambient temperature of the installation site. 
  • Consider the available power supply and voltage requirements.
  • Evaluate the available space for installation and the required minimum clearance. 
  • Determine the appropriate filtration system for your application.  

By following these guidelines, you can ensure that your selection of a Refrigerated Air Dryer will meet the specific needs of your pneumatic system and provide optimal performance. 

Please don’t hesitate to contact us if you have any further questions or require additional assistance selecting the appropriate Refrigerated Air Dryer.

Read Also: Why Compressed Air in Pneumatic Systems Must Be Dry

Air Reservoir Tank

Air Reservoir Tank has several essential functions in the pneumatic system, as follows:

Energy Storage: Energy storage is a critical aspect of pneumatic systems, and air compressors are often employed to generate pressurized air that is subsequently stored in a specialized tank. This stored energy is a backup source that can be utilized when needed, mainly when there is a sudden need for increased pneumatic power. Such an energy storage mechanism is particularly beneficial when the pneumatic system must operate continuously or when power outages are frequent.

Pressure Stability: The Air Reservoir Tank maintains stable air pressure throughout the pneumatic system. When the air compressor generates pressurized air, the pressure can increase significantly. However, the air storage tank absorbs any pressure fluctuations that may arise, ensuring that the air pressure delivered to the pneumatic components remains consistent for the system’s optimal functioning.

Eliminating Pulsation: An air tank can be a valuable addition to a pneumatic system as it helps to minimize pulsation. Pulsation is pressure fluctuation when pressurized air moves through pneumatic channels and pipes. By incorporating an air storage tank, most pulsation can be absorbed and dampened, leading to a more consistent airflow and reduced excessive stress on pneumatic components.

Removing Moisture: The air storage tank is a moisture removal system. When pressurized air is introduced into the tank, condensation may occur, converting moisture into a liquid.

One Configurator & Syntesi FRL Unit by Metal Work Pneumatic
One Configurator & Syntesi FRL Unit by Metal Work Pneumatic.

Air Filter / FRL Unit

The Air Filter / FRL Unit purifies the air by removing dust, dirt, and oil particles. This component is crucial in maintaining the air quality that enters the pneumatic system and safeguarding other components from damage. 

The filter prevents device damage and minimizes friction, component wear, and corrosion. 

Air quality plays a vital role in the production process of food and beverage, pharmaceutical, and medical industries. Therefore, selecting pneumatic system components for these industries requires careful consideration and the involvement of experienced experts. 

In these industries, cleanliness is paramount, and pneumatic systems must be regularly cleaned. 

Failure to do so can result in hazardous substances like microbes, corrosive materials, or contaminated air, disrupting production and damaging the expensive pneumatic system.

Regulator

The next component of the pneumatic system is the regulator. This component plays a crucial role in regulating the air pressure that enters the system. 

Additionally, the regulator allows for adjusting and maintaining the required air pressure based on the specific application needs. Essentially, the regulator is the pneumatic component responsible for controlling the inflow and outflow of air or gas. 

An essential feature of this component is its ability to adjust the air pressure, allowing for customization according to the pneumatic system’s requirements. Moreover, the regulator can be equipped with various safety features, such as a Pressure Relief Valve (PRV) that prevents the air pressure from exceeding the specified limit and safeguards other components from potential damage caused by excessive pressure.

Here are some tips for choosing the proper regulator for your pneumatic system:

  • Choose a regulator that fits the appropriate pressure based on your company’s application needs.
  • Choose a regulator made of solid material.
  • Consider selecting a regulator with a safety system or stopper.
  • Ensure the regulator can handle your system’s flow requirements. This is typically measured in cubic feet per minute (CFM) or liters per minute (LPM).
  • The regulator should be able to handle your system’s pressure range. It’s essential to consider both the maximum and minimum pressures.
  • Consider the environment where the regulator will be used. Some materials may not be suitable for extreme temperatures or corrosive environments.
  • The size of the regulator and its porting should match your system requirements. This includes the physical size for installation and the port size for proper flow.
  • Different types of regulators exist, such as single-stage, dual-stage, and back-pressure regulators. Choose the type that best fits your application.
  • Depending on your industry, you may need a regulator with specific certifications. Always check for these requirements.

Remember, the proper regulator can significantly enhance the efficiency and safety of your pneumatic system. Always consider your specific application needs when choosing a regulator.

Jenis-jenis Pneumatic Valve dan Prinsip Kerjanya
Solenoid Valve Circuit for Regulating Pneumatic Cylinder Motion in Industrial Applications.

Pneumatic Valve

Pneumatic valves are essential in controlling air flow within pneumatic systems. They come in several types, each designed to perform specific functions:

Directional Control Valve: This valve directs the airflow to the required device, such as an actuator or other pneumatic equipment. It can be set to different positions, including Normally Open (NO), Normally Closed (NC), or a center position, offering flexibility in system operation.

Flow Control Valve: This valve regulates the airflow rate and allows for precise control over how much air passes through the system. It’s beneficial for adjusting actuator speed and maintaining steady air pressure.

Pressure Control Valve: This valve ensures stable air pressure within the system and prevents over-pressurization and under-pressurization, safeguarding the equipment.

The solenoid valve is commonly used to control the movement of pneumatic cylinders. There are several types of solenoid valves, including:

  • 5/2 Way Solenoid Valve
  • 5/3 Way Solenoid Valve
Solenoid Valve by Metal Work Pneumatic
Various solenoid Valves by Metal Work Pneumatic.

These valves play a critical role in managing the speed and motion of pneumatic cylinders, whether for extension or retraction.

You can control the extension and retraction of the cylinder arm using solenoid valves. The speed of cylinder movement can also be fine-tuned by adjusting the exhaust flow with mufflers placed on the exhaust ports.

When selecting pneumatic valves, it’s essential to choose the right type based on your industrial application’s specific needs and characteristics. In more complex pneumatic system designs, various valve types are often used to achieve precise and optimal control.

Pressure Switch

The pneumatic system comprises several components, with the Pressure Switch being a critical element. This component detects air pressure that exceeds or falls below a predetermined threshold. 

By doing so, it safeguards the system from potential damage that could result from uncontrolled air pressure. Moreover, the Pressure Switch can activate or deactivate other components within the system as required by detecting pressure that exceeds or falls below the specified limit. 

This feature ensures the safe and efficient operation of the pneumatic system, thus making the pressure switch a vital component.

Polyurethane ELASTOLLAN C 98 by Mebra Plastik Italia
Industrial pneumatic tubing by Mebra Plastik Italia.

Pneumatic Tubing

Pneumatic Tubing is a critical component in pneumatic systems, facilitating the transfer of pressurized air between different parts. These tubes are designed to withstand air pressure and friction and are typically constructed using rubber or plastic reinforced with fibers or wire mesh.

The advantage of pneumatic tubes is their exceptional flexibility, with options ranging from soft to rigid. They are used in diverse industries, such as food and beverage, medical, automotive, and more. 

Quality pneumatic tubing offers numerous benefits across various sectors, as outlined below:

  • High resistance to temperature and pressure.
  • Resistance to damage from chemicals, corrosive substances, or flammable materials.
  • Flexibility to connect various components in different positions and challenging to reach.
  • A wide range of options for various industries in terms of raw materials, hose structure, size, and high standardization to meet American and European regulations.

Although pneumatic tubes are not made of metal, some products exhibit the same durability as metal. For instance, certain Pneumatic Tubing products from Mebra Plastik Italia can withstand high pressure and temperature.

Rilsan PA 11 PHL by Mebra Plastik - Bawalaksana ID
Rilsan PA 11 PHL by Mebra Plastik.

When selecting pneumatic hoses for industries such as automotive, food and beverage (F&B), pharmaceuticals, or medical devices, adherence to internationally recognized standards is essential. Standards such as UL94 V2, ISO 7628 Ed. 2010 and FDA Title 21 are examples of benchmarks that ensure compliance with industry regulations.

Several key factors should be considered when choosing the appropriate pneumatic hose for specific applications:

  • Pressure Resistance: It is crucial to select a hose with adequate pressure resistance tailored to the precise demands of the company’s applications.
  • Chemical Resistance: For applications involving chemicals or corrosive substances, it is imperative to choose hoses specifically designed to withstand these conditions.
  • Abrasion and High-Pressure Resistance: In harsh environments, hoses resistant to both abrasion and high pressure may be necessary for operations.
  • Length Requirements: Ensuring that the required hose length matches the system’s needs is essential for optimal performance.
  • Material Selection: Pneumatic hoses are typically made from rubber, plastic, or synthetic compounds. The choice of material should align with the application’s operational conditions, considering factors such as flexibility, durability, or chemical compatibility.
  • Correct Diameter: Determining the appropriate diameter for the hose based on the company’s needs is crucial. Pneumatic hose vendors often provide size charts to assist in selecting the correct size for specific applications.

Thorough consideration of these factors enables the selection of pneumatic hoses that enhance system efficiency and safety and ensure compliance with industry standards.

Read Also: 11+ Best Heat-Resistant Hoses for High-Temperature Applications
Berbagai jenis fitting dan konektor untuk sistem pneumatik by Metal Work
A Wide Range of Fittings and Connectors for Pneumatic Systems by Metal Work.

Pneumatic Fittings

Fittings play a crucial role in pneumatic systems by connecting hoses to other components. Typically made from metal or plastic, fittings come in various types, including connectors, couplings, and adapters. 

Pneumatic fittings securely and hermetically join hoses to other devices. Properly selecting pneumatic hoses and fittings is essential for optimal system performance, as it prevents air leaks that could compromise efficiency. 

When implementing a pneumatic system, carefully consider the fitting’s size and type.

Silinder Pneumatik - Jenis dan Cara Kerjanya - Bawalaksana ID
Various pneumatic cylinders by Metal Work.

Pneumatic Cylinder 

Pneumatic cylinders are components that can convert compressed air energy into mechanical motion. Their working principle is based on converting air pressure into mechanical force, which enables the movement of the piston inside the cylinder.

Pneumatic cylinders are commonly utilized to generate linear motion, allowing the piston to move forward and backward. However, the design and configuration of the cylinder can impact its ability to generate motion. As a result, devices are available that can produce rotational motion or a combination of both.

When selecting the appropriate pneumatic cylinder, it is crucial to consider several factors.

  • Application Type: When considering the pneumatic cylinder for your project, it is essential to identify the specific application it will be used for. Will it be utilized in the automotive industry, the food and beverage sector, the pharmaceutical field, the medical field, or other industrial applications? Understanding the intended application will provide valuable insight into the pneumatic cylinder’s requirements.
  • Lifting Force and Power: Determine the pneumatic cylinder’s required lifting force. This depends on the load that needs to be lifted or moved.
  • Type of Movement: Choose the appropriate kind of movement, whether linear, rotational, or a combination of both.
  • Cylinder Size: When selecting a pneumatic cylinder, it is vital to consider its physical size. This includes the length, diameter, and overall dimensions of the cylinder. It is crucial to ensure that the dimensions of the cylinder are suitable for the available space in the application.
  • Speed and Accuracy: When considering pneumatic cylinders, it is essential to consider the maximum speed needed and the desired level of accuracy. This will help determine the most suitable type of cylinder to provide the required speed and accuracy. If high accuracy is a priority, opting for an electrical actuator is recommended.
Read Also: Understanding Pneumatic Cylinders: Components, Types, and How They Work
Pneumatic Valve & Controller by Metal Work Pneumatic - Bawalaksana ID
Pneumatic Valve & Controller by Metal Work Pneumatic – Bawalaksana ID

Controller

Controllers in Pneumatic Systems

Controllers in pneumatic systems can include switches, hand levers, or buttons. Each serves to activate or deactivate the system and manage the operations of various components.

Switches and Buttons: These devices control the airflow to pneumatic components. When activated, a switch opens the air pathway, allowing compressed air to flow to the intended component. Conversely, when the switch is turned off, it closes the pathway, halting the airflow.

Hand Levers: Hand lever controllers can perform multiple functions, such as operating pneumatic cylinders, regulating airflow, or adjusting pressure within the system. Typically, hand levers have two positions: active and inactive. Pressing the lever activates the desired function, and releasing it returns the lever to its inactive position.

Controllers like switches and buttons are often integrated into control panels or valve modules to streamline the operation of compressed air systems.

EB80 Pneumatic Module Valve - Integrated to PLC (Programmable Logic Controller) - Bawalaksana ID
The EB80 Pneumatic Module Valve is ready to integrate with PLC.

In modern pneumatic circuits, automation is frequently achieved through solenoid valves and PLCs (Programmable Logic Controllers). As seen in the image above, the EB80 Island Valve module is a notable tool for this application.

The EB80 module is designed for contemporary pneumatic systems. It automatically regulates airflow to various pneumatic cylinders and offers user-friendly control over the logical functions of each valve and cylinder.

The EB80 valve module can also be connected to a PLC to facilitate advanced pneumatic system automation. This module can record data related to pneumatic cylinder response times, usage cycles, and predictive maintenance.

The introduction of this module signifies a revolutionary shift for pneumatic devices in the context of Industry 4.0. With sophisticated valve modules, pneumatic systems demonstrate enhanced adaptability to technological advancements (Read: 4 Advantages of Pneumatic Systems You Need to Know).

In the current era of Industry 4.0, technology flexibility is essential for effective automation systems. By merging pneumatic devices with modern technology, automation systems in your industry can achieve greater efficiency and effectiveness.

The following video illustrates an example of a pneumatic system application in the medical mask manufacturing industry:

Komponen sistem pneumatik dan cara kerja - Bawalaksana ID
Pneumatic automation parts and components by Metal Work.

Why Choose High-Quality Pneumatic Components Important?

Investing in high-quality pneumatic components can bring companies a multitude of benefits. They enhance the performance and reliability of pneumatic systems and can also significantly impact cost efficiency, productivity, and downtime. 

By choosing the right components for a specific application, companies can ensure optimal performance, reduced maintenance costs, and extended equipment service life. 

High-quality pneumatic components can help minimize the risk of system failures, resulting in costly downtime and lost productivity. 

Let’s explore some key benefits of selecting high-quality pneumatic components:

Reliable Performance

High-quality pneumatic components provide dependable and consistent performance. These devices are engineered with state-of-the-art technology to meet rigorous industry standards. This is done to guarantee efficient and long-lasting operation of pneumatic devices.

Extended Service Life

High-quality pneumatic components are engineered for durability and constructed from robust materials capable of withstanding prolonged pressure and wear.

A prolonged service life can substantially reduce maintenance expenses and the frequency of component replacements for your organization.

It is important to emphasize that pneumatic devices are renowned for their ease of maintenance. Their components are meticulously designed to ensure high durability and reliability.

However, inadequate knowledge of proper pneumatic system maintenance may lead to various issues. Here are some crucial considerations:

  • Maintain Clean and Dry Air: Ensure the air supply is free from contaminants and moisture.
  • Prevent Water Accumulation: Regularly inspect and prevent water buildup along air lines to avoid performance issues.
  • Drain Accumulated Water: Regularly eliminate water accumulation from various components to preserve optimal functionality.
  • Utilize Industry-Specific Pneumatic Hoses: To ensure compatibility and performance, choose hoses that adhere to relevant industry specifications.
  • Regular Maintenance of FRL Devices: Consistently upholds FRL (Filter, Regulator, Lubricator) devices, solenoid valves, and pneumatic cylinders to improve system efficiency and longevity.

Adhering to these best practices can optimize the performance and lifespan of your pneumatic systems, ensuring dependable operation and reduced operational costs.

Read Also: 10 Essential Steps for Maintaining Pneumatic Systems

Energy Efficiency

High-quality pneumatic components are designed to optimize energy usage. These devices have precise and responsive control systems. Avoiding air leaks and minimizing unnecessary energy consumption are important. Using high-quality pneumatic components can save energy and reduce operational costs in your company. 

Additionally, the implemented pneumatic system in your company can function correctly. 

When low-quality pneumatic components are used, they become more susceptible to air pressure system leaks. This can significantly increase production costs, amounting to $38,000 per year.

For more information on this topic, please refer to our article, “3 Key Factors for Optimal Pneumatic System Performance.”

Security and Safety

High-quality pneumatic components are engineered with a strong focus on safety, featuring fail-safe valves, pressure sensors, and emergency stop mechanisms.

These safety features prevent accidents and equipment damage due to overpressure or component failure.

As outlined in this article, selecting premium pneumatic components is more than a short-term decision; it’s a strategic investment with long-term advantages. From improved performance and efficiency to increased productivity and safety, the benefits of dependable pneumatic systems resonate across all aspects of your operations.

Pneumatic automation system implementation by Metal Work Pneumatic
Pneumatic automation system implementation by Metal Work Pneumatic

The components highlighted here are just some critical elements in pneumatic system automation. It’s worth noting that several other vital components, while not mentioned, also play crucial roles.

Throttle valves, check valves, and accumulators are some of these, which are commonly used in specialized applications.

Additionally, essential components like desiccant air dryers, drain valves, and water separators, though not covered here, are critical for maintaining dry air within the system and effectively removing water accumulation in pneumatic circuits.

*****

PT. Bawalaksana Central Industrial is the authorized distributor for pneumatic system products from Metal Work Pneumatic and pneumatic hoses from Mebra Plastik Italia. Our company specializes in providing tailored solutions for the design and automation of pneumatic systems, specifically tailored to meet the unique requirements of various industrial operations.

With a longstanding presence since 2017, we have established ourselves as a reliable industrial automation equipment supplier. We offer extensive expertise in recommending the most appropriate pneumatic components for diverse business needs.

Our team comprises accomplished engineers who are well-equipped to support you in strategically planning and designing optimized pneumatic systems. These systems aim to enhance cost efficiency and elevate productivity to new heights.

Reach out to our Sales Engineer today for precise and dependable recommendations.


Romanta Pinrih Linuwih - Managing Director at PT. Bawalaksana Central Industrial - Square

Romanta Pinrih Linuwih

Pneumatic Automation Systems Expert

This article was written in collaboration with Romanta Pinrih Linuwih, an expert in Pneumatic Automation Systems, to ensure accuracy and high quality.

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