Pneumatic training kit

About Pneumatic training kit

A brief introduction of the Pneumaticsystem employed in the Training Kit

This Pneumatic Training Kit has beendesigned to provide a firsthand knowledge of how a pneumatic system works. Inrecent times there has been wide spread usage of pneumatic systems for havingvarious types of automated movements to accomplish a job. As such automationhas become an integral part of pneumatic systems. Pneumatic systems are mostlyused for achieving automated movements whereas hydraulic systems are employed mainlyto handle large loads.

In our system there are two Cylindersnamely A which is single acting and B which is double acting. These Cylindersare activated with high pressure air supplied by a Compressor and fed through aFRL. The FRL is a combination of a Filter,used to eliminate the ingress of dust particles to the system and a Regulatorto control and adjust the pressure ofair to the system and a Lubricator to provide necessary lubrication to the pneumaticcomponents to minimize wear and tear. This high pressure air when entersthe bottom or top port of a doubleacting Cylinder an upward or a downward thrust is created resulting in upward or downward movement ofthe plunger respectively. In single acting cylinder there is only inlet portand the upward piston movement is achieved by the thrust created by incominghigh pressure air and the downward movement of the piston is achieved by thepull of gravity when the upward thrust is withdrawn by cutting of the airsupply.

In the pneumatic circuit SV₁ isthe mother solenoid valve (2/2) providing supplies to all the destinations.This is a simple on and off valve resuming or cutting off air suppliesdepending on whether the solenoid coil is energized or not.

SV₂ is a 3/2 solenoid valveproviding pressurized air to Cylinder A when the solenoid coil isenergized causing upward movement of thecylinder plunger and dumps the cylinder air to the atmosphere when the solenoidcoil is de-energized resulting indownward movement of the plunger due to the action of gravity.

SV₃ and SV₄ are2/2 solenoid valves as SV₁ and supplies pressurized air to the TwoPressure Valve. Two Pressure Valve has been used to apply simple logic tofacilitate automatic control. When both the inlets of Two Pressure Valve aresupplied with high pressure air an output of pressurized air is available atthe outlet port of the valve which is then applied at the pilot port of a 5/2Pilot operated Pneumatic valve. However, if any of the two inputs to the Two Pressurevalve is withdrawn the valve will fail to provide an output. The pilot operatedpneumatic valve causes downward movement of the plunger of double acting CylinderB when there is no pilot pressure and causes a reversal of direction resultingin upward movement of the plunger of Cylinder B when a pressure is applied atthe pilot port of the valve. When both SV₃ and SV₄solenoid valves are energized upward movement of the plunger of cylinder B isachieved. When any of these two solenoid valves namely SV₃ and SV₄is de-energized the pilot operated 5/2 pneumatic valve should causereversal of plunger movement of Cylinder B. However, despite withdrawal ofsupply of air from Two Pressure Valve there will remain some residual pressurein the pilot line preventing any such reversal of direction. Hence, asolenoidvalve SV₅ has been introduced to release the residual pressure. SV₅is a 3/2 solenoid valve like SV₂. When SV₅ is on itconducts available high pressure air to the pilot port of the Pilot operatedPneumatic Valve and when SV₅ is off_, it relieves residualpressure of the pilot line to the atmosphere_. SV₅ is switchedon when both SV₃ and SV₄ are on causing upward movementof the plunger of cylinder B andSV₅ is switched off whenany of SV₃ and SV₄ is switched off causing reversal ofdirection as already stated. The solenoid valves get actuated by the operationsof limit switches fitted with Cylinder A and Cylinder B. These limit switchesare pressed on and off by the movements of the plungers of both the Cylinders.

Besides above a quick release valvehas been provided with the single acting Cylinder to achieve fast downwardmovement of the plunger of the Cylinder A.

There are three types of automated movementsunder the category of Option 1, Option 2 and Option 3 which have been explainedin detail in the following pages.

Comprehensive Training Solution

This kit is engineered to provide hands-on experience in pneumatic systems for both educational institutions and industrial training centers across India. Modular design and clear labeling make it easy for users to identify and understand various components, enhancing learning outcomes. The tabletop form factor and portable construction allow training anywhere indoors, provided the environment is dry and dust-free.


Versatile Components for Realistic Simulations

Featuring high-quality components such as directional and flow control valves, pneumatic cylinders, pressure gauges, and FRL units, the kit replicates actual industrial pneumatic systems. These elements, combined with manual or solenoid-based operation and an analog pressure display, ensure realistic demonstrations and practical skill development for automotive and mechanical applications.