The operation of a Pneumatic System centers on directing compressed air from a compressor to a pneumatic cylinder, converting air pressure into mechanical motion. This process relies on several critical components, including an air filter, regulator, solenoid valve, and controller.
In this article, the Bawalaksana team will explain how pneumatic devices function and explore the essential components commonly used in these systems.
How Pneumatic Systems Work & Components
The operation of pneumatic systems is based on using compressed air acquired from a compressor, which is then directed to the FRL unit, valves, and, subsequently, to the pneumatic cylinder devices.
The compressed air from the compressor traverses through pneumatic pipes and hoses, interconnecting all pneumatic system elements. It is imperative to emphasize the need for proper and regular maintenance of pneumatic devices. This practice is essential to ensure each component’s efficient operation and minimize the likelihood of damage.
Adhering to appropriate maintenance protocols for pneumatic systems can help the system achieve and sustain optimal performance levels while mitigating significant issues.
The essential components of pneumatic systems include:
- Air Compressor
- Refrigerated Air Dryer
- Air Reservoir Tank
- Water Separator
- Air Filter (FRL unit)
- Pneumatic Hose
- Solenoid Valve / Pneumatic Valve
- Drain Valves
- Pneumatic Cylinder (Pneumatic Actuator)
- Others
Utilizing clean and dry compressed air is crucial to ensuring the efficient operation of pneumatic devices. Compressed air is the system’s primary energy source, enabling it to function optimally.
Several methods are available to obtain compressed air, including using an Air Compressor, an Air Reservoir Tank filled with compressed air, or nitrogen cylinders.
In the following section, we will provide a detailed explanation of how pneumatic systems work, along with the components involved, as outlined below:
Compressing Air
The air compressor draws in and compresses air from the surrounding atmosphere. The compressed air is then directed to the refrigerated air dryer or stored directly in the air reservoir tank.
Eliminating Air Moisture
It is essential to remove moisture before air is used in pneumatic systems. The Refrigerated Air Dryer achieves this by rapidly cooling the compressed air to a Pressure Dew Point (PDP) of 3°C (37.4°F). It causes the moisture to condense into liquid form, which is then drained through a waste outlet.
Once the moisture is eliminated, dry compressed air is produced and ready to be stored in the air reservoir tank. Dry air is essential for the system’s efficiency and longevity, as it prevents corrosion and extends the lifespan of pneumatic components. In contrast, allowing moist air into the system can degrade performance and lead to equipment failure.
Storing Air in the Reservoir Tank
After passing through the Refrigerated Air Dryer, the compressed air is stored in the Air Reservoir Tank. This storage offers several key benefits, including:
- Providing an energy reserve
- Maintaining stable air pressure throughout the system
- Reducing pulsation and excessive stress on pneumatic components
- Further decreasing air moisture
The Air Reservoir Tank is vital in ensuring a stable, dry air supply for the system and serves as an energy reserve for sudden spikes in pneumatic power demand. Compressed air is distributed to all devices via pipes or pneumatic hoses from the storage tank.
Distributing Air Throughout the System via Pneumatic Hoses
The next stage involves channeling compressed air to all devices and components through pneumatic hoses. These hoses are the lifeline of the pneumatic system, delivering the compressed air necessary to power each component.
For optimal performance, it is crucial to use high-quality hoses that meet industry standards. Common materials for industrial pneumatic hoses include:
- Polyamide (PA)
- Polyurethane (PU)
- Polyethylene (PE)
- Fluoropolymer
After leaving the Air Reservoir Tank, the compressed air is directed to the Air Service Unit or FRL Unit for further processing.
Filter, Regulator, Lubricator (FRL Unit)
In pneumatic systems, compressed air must be filtered and lubricated to remove dust particles and ensure the smooth operation of moving components.
The FRL unit—comprising a Filter, Regulator, and Lubricator—fulfills these functions while also regulating air pressure to industry standards, typically between 5-10 BAR (500-1000 kPa / 72.5-145 psi).
The FRL unit’s lubrication process releases an oil mist into the pneumatic channel, providing necessary lubrication for components such as the solenoid valve, pneumatic cylinder, and other moving parts (e.g., air tools).
Controlling Air Supply with Solenoid Valves
After passing through the FRL unit, the compressed air is directed to the solenoid valve. This component controls the airflow to the pneumatic cylinder, regulating its speed and stroke movement (extension or retraction).
These solenoid valves can operate manually via a hand lever or integrated with a Programmable Logic Controller (PLC) for automated control.
Common types of solenoid valves used in the industry include:
- 5/2 Way Solenoid Valve
- 5/3 Way Solenoid Valve
- Normally Closed (NC) Solenoid Valve
- Normally Open (NO) Solenoid Valve
Generating Mechanical Motion with Pneumatic Cylinders
Pneumatic cylinders transform compressed air into mechanical motion. The motion of the cylinder is regulated by a solenoid valve, which manages the airflow to the air ports positioned at the front and rear of the cylinder.
When air is directed to the rear end, the piston rod extends; conversely, when air is directed to the front, the piston rod retracts.
For a more comprehensive understanding of pneumatic cylinder operation, please consult our article, “Understanding Pneumatic Cylinders: Components, Types, and How They Work.”
It is pertinent to recognize that practical applications of pneumatic systems frequently entail more intricate configurations, as different industries have diverse requirements for them.
The diagram below provides a visual depiction of the general working process of a pneumatic system:
To ensure efficient functionality and alignment with industrial requirements, pneumatic automation systems necessitate meticulous design.
In the context of Industry 4.0, contemporary pneumatic systems can be seamlessly integrated with digital technologies or IoT solutions, augmenting their efficacy.
One of the pneumatic solutions for this purpose is the EB80 System from Metal Work Pneumatic.
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 pneumatic cylinder response times, usage cycles, and predictive maintenance data.
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
The EB80 Valve Module plays a crucial role in achieving high energy efficiency within pneumatic systems. This advanced technology is instrumental in recording historical data at the machine level—capturing essential metrics from cylinders, valves, and sensors—and can securely store it within its microprocessor for up to 50 years.
Monitoring data at the pneumatic level is essential for conducting quantitative and qualitative analyses of operational and performance metrics in pneumatic automation systems.
Explore our detailed guide on How to Boost Pneumatic System Efficiency for Sustainable Manufacturing for more insights.
For a comprehensive understanding of industrial applications, we invite you to explore our article “15+ Industries Utilizing Pneumatic Systems,” which offers an in-depth exploration of diverse implementation scenarios.
Additionally, the accompanying video visually portrays pneumatic system operations, elucidating the functions of individual components.
Key Components of Pneumatic Systems
Pneumatic systems rely on several essential components to function effectively, including:
- Air Compressor
- Refrigerated Air Dryer
- Air Reservoir Tank
- Pneumatic Hoses
- Solenoid Valve
- Pneumatic Cylinder
- Controller / Hand Lever
- FRL Unit (Filter, Regulator, Lubricator)
- Fittings
At their core, pneumatic systems can operate with just a few essential components, such as:
- Air Compressor
- Pneumatic Hoses
- Pneumatic Valve with Hand Lever
- Pneumatic Cylinder
While these simple setups are functional, industrial applications require more advanced components to ensure the system operates efficiently, safely, and reliably. Proper system design, including integrating sophisticated devices and regular maintenance, is essential for long-term success in industrial environments.
Furthermore, expert knowledge and adequate training are necessary to maintain high levels of efficiency and productivity in pneumatic systems.
For a more in-depth look at pneumatic components and their functions, please refer to our article, “10+ Components of Pneumatic System You Need to Know.”
Implementation of Pneumatic Systems in Modern Industry
Pneumatic systems offer a cost-effective solution for automation devices requiring linear and rotational motion. Did you know these systems are widely used in modern industries, including manufacturing and aerospace?
According to Techbrief, today’s pneumatic systems increasingly integrate innovative technology and advanced sensors. It enables seamless interaction with other systems, allowing pneumatic devices to operate autonomously and enhancing both cost efficiency and productivity.
Due to pneumatic systems’ numerous advantages, they have become a top choice in the manufacturing sector. Indonesia, in particular, has shifted its export strategy from commodity-based to manufacture-based, aiming to improve its domestic trade balance.
This concludes our discussion on the working mechanisms and critical components of pneumatic systems in industrial and automation settings. If your company is considering implementing pneumatic system automation, we are here to be your trusted partner in realizing that goal.
PT. Bawalaksana Central Industrial is the authorized distributor of Mebra Plastik Italia, a leading manufacturer specializing in pneumatic hoses and industrial tubing. We are also the authorized distributor for Metal Work Pneumatic, which produces a comprehensive range of pneumatic devices and components.
With over seven years of experience in industrial automation, we can provide expert recommendations on pneumatic automation solutions. Please speak with our engineering team to discuss and plan to implement an effective pneumatic system.
Begin integrating modern pneumatic technology today to boost your company’s productivity to the next level.
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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.
