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CAMOZZI AUTOMATION
Pneumatic automation from basic principles to practical techniques EN

Pneumatic automation from basic principles to practical techniques EN

Product catalog summary

Introduction
Camozzi Automation S.p.A. is a leader in pneumatic automation, providing high-quality solutions for various industrial sectors. The document highlights the importance of education in pneumatics, with the Camozzi Competence Centre offering continuous training and resources.

The Importance of Education in Pneumatics
Structured educational programs are essential to keep up with technological advancements. The Camozzi Competence Centre ensures employees, suppliers, and clients are equipped with both theoretical and practical knowledge.

Utilization of Pneumatic Automation in Industry
Pneumatic automation is versatile and high-performance, crucial for industrial processes. Understanding product operation and application principles fosters innovation and growth.

Camozzi Technology and Tailor-Made Solutions
Camozzi Automation is a global leader offering customized solutions through research and development, operating six manufacturing plants with a focus on lean production and technological innovation.

Chapter Summaries

Chapter 1: Physics - Covers basic principles like atmospheric pressure and Boyle’s law.
Chapter 2: Air Production and Preparation - Discusses compressors and air treatment.
Chapter 3: Cylinders - Explains cylinder operation and performance modification.
Chapter 4: Valves - Details valve types and applications.
Chapter 5: Circuit Technique - Guidelines for designing pneumatic circuits.
Chapter 6: Electro-Pneumatic Circuits - Integrating electrical and pneumatic systems.

Key Concepts and Principles
Includes explanations of gas behavior under pressure, atmospheric pressure impact, and pneumatic and electro-pneumatic systems principles, with practical examples and calculations.

Conclusion
Camozzi Automation emphasizes continuous learning and innovation in pneumatic automation to meet industrial sector demands, serving as a comprehensive guide to pneumatic principles.

Pressure Equilibrium and Boyle's Law
Discusses pressure equilibrium and Boyle's Law, stating that at constant temperature, gas volume is inversely proportional to pressure.

Temperature Effects on Gases
Explains how gases change volume with temperature changes, using Gay-Lussac's laws.

Practical Applications and Examples
Illustrates calculations of volume and pressure changes using Boyle's and Gay-Lussac's laws.

Relationship Between Pressure, Volume, and Temperature
Summarizes the interdependence of pressure, volume, and temperature with practical problems.

Volume and Pressure Calculations
Discusses Gay-Lussac's laws application in pneumatic systems, providing formulas and calculations.

Pressure and Flow Rate
Explains pressure and flow rate concepts in pneumatics, using examples and Torricelli’s law.

Pascal’s Principle
Explores Pascal’s principle, demonstrating pressure consistency across system sections.

Venturi’s Principle
Discusses Venturi’s principle, highlighting fluid velocity and pressure changes in constricted tubes.

Mechanical Concepts
Covers basic mechanical concepts like force, work, velocity, and equilibrium of forces.

Sliding and Rolling Friction
Explains sliding and rolling friction, influenced by material, surface finish, and contact force.

Force Calculations
Provides calculations for static, kinetic, and rolling friction forces, and work done.

Magnetism and Electromagnetism
Describes magnetism and electromagnetism, including magnetic fields and solenoids.

Air Production and Preparation
Discusses compressors, air treatment, and pressure regulation, emphasizing air quality and efficiency.

Air Compression and Cooling
Details air compression and cooling processes, including water removal and cooling methods.

Distribution Networks
Explains primary and secondary network configurations for air distribution.

Pipe Size Calculations
Describes methods for determining correct pipe diameter based on flow rate and pressure drop.

Air Treatment and Filtration
Emphasizes the importance of removing impurities from compressed air.

Pressure Regulation
Explains pressure regulator operation and relieving function.

Isolation Valves
Describes isolation valves and their role in air treatment units.

Soft Start Valves
Explains soft start valves' function in controlling piston movement speed.

Pressure Regulators Without Compensation
Discusses energy-saving pressure regulators without compensation chambers.

Relief Valves
Used to maintain constant pressure by discharging excess air.

Lubricators
Describes the need for additional lubrication in pneumatic systems.

Cylinder Operation Principles
Explains pneumatic cylinders' force generation and sealing importance.

Specifications and Calculations
Analyzes pistons and calculates thrust forces, demonstrating relationships between diameter, pressure, and force.

Component Parts and Terminology
Details pneumatic cylinder components and their functions.

Pressure Dynamics
Explains pressure dynamics in double-acting cylinders.

Force Development
Discusses force development in single and double-acting cylinders.

Constructive Characteristics
Outlines different pneumatic cylinder types and construction materials.

Sizing and Application
Explains cylinder sizing based on load and performance factors.

Specifications and Procedures
Discusses braking systems in pneumatic cylinders and cushioning phase effectiveness.

Graph Analysis
Analyzes graphs illustrating load and piston speed relationships.

Cushioning Systems
Describes adjustable cushioning systems in cylinders.

Acceleration Phase
Explains the starting phase of pneumatic cylinders.

Cylinder Brackets
Describes brackets for fixing cylinder bodies and minimizing radial loads.

Piston Rod Mountings
Discusses proper alignment of piston rods to avoid wear.

Rod Stress and Compression Load
Explains compression load and standards for rod length and diameter.

Installation Examples
Provides examples of different installation types and their impact on stroke length.

Key Diagrams
Includes diagrams for determining cylinder and rod dimensions.

Specifications
Discusses installation types and maximum stroke lengths for cylinders.

Lever Mechanism
Explains lever use in modifying cylinder performance.

Crank Handle
Describes crank transformation of cylinder movement into angular movement.

Geared Mechanisms
Explains gear use in converting linear to circular motion.

Wedge Mechanism
Describes wedge use as a blocking device in pneumatic systems.

Rotary Cylinders
Discusses rotary cylinders and their applications.

Specifications and Procedures
Includes torque calculation and applications for various mechanisms.

Magnetic Cylinders
Describes magnetic cylinders with proximity switches.

Special Purpose Cylinders
Discusses opposed, tandem, multi-position, and rod-less cylinders.

Air Consumption and Cost
Calculates free air consumption and cost based on operational parameters.

Hydrochecks
Used for speed control in pneumatic systems.

Overview
Provides a technical analysis of pneumatic systems, focusing on cylinder and valve operation.

Hydrocheck Speed Regulation
Describes hydrocheck use for precise speed regulation.

Pressure Booster
Used for increasing supply pressure in space-constrained scenarios.

Valves Overview
Discusses valve types and their roles in pneumatic systems.

Poppet Valves
Explains poppet valve design and operation phases.

Spool Valves
Describes spool valve configurations and functions.

Key Calculations
Includes calculations for outgoing pressure determination.

Figures and Diagrams
Illustrates cylinder and valve operations with diagrams.

Overview
Provides technical information on valve types and manual control mechanisms.

Valve Positions and Operations
Explains valve positions and operations in pneumatic systems.

Manual Operation of Poppet Valves
Describes manual operation methods for poppet valves.

Mechanical Operation
Discusses mechanical switches for valve operations.

Mini Poppet Valves
Designed for compactness and small tube diameters.

Spool Valves
Describes 3/2-way and 5/2-way spool valves.

Manual and Mechanical Operating Devices
Explains manual and mechanical control devices for valves.

Overview
Provides a technical analysis of solenoid valves in pneumatic systems.

Valve Types and Symbols
Describes valve types and symbols for identification.

Pneumatic Operating Devices
Categorizes valves into direct and indirect control types.

Solenoid Valves
Details solenoid valve components and operation.

3/2-way and 2/2-way Solenoid Valves
Explains operation of NC and NO solenoid valves.

Applications
Discusses typical applications of solenoid valves.

Key Considerations
Stresses understanding pressure, orifice size, and solenoid force relationships.

Overview
Provides a technical analysis of solenoid valves in pneumatic systems.

Specifications
Describes solenoid valves designed for reduced dimensions and low power consumption.

Types of Solenoid Valves
Describes internal and external servo pilot valves.

Three-Position Valves
Offers a third position through a repositioning spring.

Blocking Valves
Used to stop pneumatic cylinders during their stroke.

Key Diagrams
Includes diagrams illustrating valve configurations.

Applications
Used in applications requiring precise control of pneumatic systems.

Double Acting Cylinder with Intermediate Stop
Describes operation of a double acting cylinder with an intermediate stop.

Double 2/2-way and 3/2-way Valves
Describes integration of two spools into one valve body.

Signal Processing Valves
Used for processing signals in pneumatic circuits.

Logic Function NOT
A 3/2-way NO monostable valve for low-pressure pilot signals.

Logic Function YES
A 3/2-way NC monostable valve for pneumatic logic circuits.

Logic Functions OR and AND
Used in pneumatic circuits to control signal passage.

Logic Function Memory
Supplies a signal based on the last received pneumatic command.

Signal Amplifier
A monostable 3/2-way NC valve that amplifies low-pressure pilot signals.

Specifications and Procedures
Discusses operation of pneumatic valves and sensors.

Nominal Flow Rate and Valve Sizing
Emphasizes sizing valves based on flow rate.

Directional Control and Tube Sizing
Details calculations for valve and tube sizing.

Interception and Quick Exhaust Valves
Describes unidirectional and quick exhaust valves.

Flow Control Valves
Adjust air flow to regulate piston speed.

Flow Regulation and Valves
Discusses operation of flow regulation valves.

Flow Regulator Analysis
Demonstrates effect of flow regulators on cylinder performance.

Valves with Vacuum
Examines use of valves with vacuum.

Pressure Switches
Ensure system operation within required pressure ranges.

Circuit Techniques
Covers air preparation, cylinder types, and directional control valves.

Introduction
Provides a guide on designing circuits for electric and pneumatic systems.

Designing Circuits
Explains circuit composition and symbol representation.

Valves and Cylinders
Describes valve and cylinder representations and operations.

Elementary Circuits
Controls single cylinders using 3/2-way valves.

Double-Acting Cylinders
Requires air flow in two directions, controlled by 5/2-way valves.

Indirect Control
Involves using a pilot valve for remote operation.

Single or Semi-Automatic Cycle
Describes circuits with defined actuator sequences.

Continuous or Automatic Cycle
Uses additional valves for automatic cycle repetition.

Overview
Explains pneumatic circuit operations and valve functions.

Main Sections

Valve Operations: Explains pneumatically operated bistable 5/2-way valve operation.
Elementary Circuits: Introduces 5-way/3-position valves with different centers.
Literal and Graphical Representation: Describes cylinder movement representation.
Flow Diagrams: Provides examples of flow diagrams for operations.
Limit Switch Signals: Discusses role of limit switches in controlling movements.
Continuous Cycle Operations: Details signals for continuous cycle operations.

Key Points

Understanding valve positions and limit switch activations is crucial.
Different valve configurations have specific applications.
Accurate representation of cylinder movements is essential.
Flow diagrams are valuable for visualizing operations.
Continuous cycle operations require careful signal management.

Introduction
Analyzes pneumatic automation circuits, focusing on logic principles and functions.

Specifications and Procedures
Outlines pneumatic cylinder operation and limit switch roles.

Logic Principles
Explains basic logic functions applicable to pneumatic systems.

Application Examples
Illustrates logic function applications in pneumatic systems.

Logic Functions in Pneumatics
Details pneumatic valve use for logic functions.

Conclusion
Emphasizes understanding logic functions for efficient automation.

Overview
Analyzes pneumatic circuit techniques, focusing on valves and memory functions.

Specifications
Outlines use of 3/2-way and 5/2-way valves for signal management.

Procedures
Describes memory valve use for signal handling.

Norms and Recommendations
Recommends valve types and emergency command design.

Key Diagrams and Figures
Includes figures illustrating valve and circuit configurations.

Critical Information
Highlights importance of valve selection and emergency mechanisms.

Introduction
Outlines pneumatic circuit operation sequence involving multiple cylinders.

Specifications and Sequence Development
Describes sequence development for cylinder operations.

Circuit Analysis
Analyzes circuit using 5/2-way and 3/2-way valves.

Safety and Operation Conditions
Details safety conditions for operation.

Flow Diagram and Pneumatic Circuit Design
Outlines sequence phases and safety conditions.

Movement of Multiple Cylinders
Describes cycle involving multiple cylinders.

Signal Identification and Blocking
Identifies and manages different signal types.

Conclusion
Analyzes pneumatic circuit operation, emphasizing sequence and safety.

Overview
Discusses pneumatic cylinder operation using limit switches and signals.

Signal Descriptions

Signal c1: Generates negative stroke of cylinder A.
Signal a0: Generates negative stroke of cylinder C.
Signal c0: Generates negative stroke of cylinder B.
Signal b0: Generates positive stroke of cylinder A.

Sequence Analysis
Analyzes sequences and identifies blocking signals.

Techniques to Eliminate Blocking Signals

Mechanical Control Removal: Removes mechanical control of limit switch.
Air Supply Control: Controls air supply to limit switch.
Signal Control: Controls signal generated by limit switch.

Flowchart and Sequence Phases
Includes flowcharts illustrating sequence phases.

Alternative Solutions
Discusses solutions like unidirectional roller levers.

Conclusion
Provides strategies to ensure smooth pneumatic circuit operation.

Overview
Explains pneumatic circuit techniques using memory valves in cascade.

Specifications
Describes system with cylinders performing tasks in sequence.

Procedures
Details sequence phases and memory valve activation.

Norms and Recommendations
Emphasizes correct configuration of memory valves and limit switches.

Key Data and Figures
Includes figures illustrating operation phases.

Critical Information
Stresses avoiding unintended limit switch activations.

Overview
Explains pneumatic circuit system operation using memory valves and sequencers.

Specifications
Uses memory valves and limit switches for cylinder sequence control.

Procedures
Describes step-by-step circuit operation.

Norms and Recommendations
Emphasizes safety and emergency function analysis.

Key Data and Figures
Includes figures illustrating circuit layout and operations.

Critical Information
Relies on bistable and monostable valves for sequence control.

Conclusion
Provides a guide to pneumatic circuit system implementation.

Pneumatic and Electrical Systems
Describes pneumatic and electrical system components and diagrams.

Relay Circuits
Explains relay operation and circuit control.

Logic Functions
Describes identity, negation, and memory functions in circuits.

Control Systems
Explains electro-pneumatic circuit operation using solenoids.

Solenoid Valve Activation
Discusses monostable and bistable solenoid valve operation.

Cylinder Cycles
Describes single and continuous cylinder cycles using solenoid valves.

Overview
Analyzes electro-pneumatic circuits and logic functions.

Logic Functions

YES Function: Energizes solenoid with button activation.
NOT Function: De-energizes solenoid with button activation.
AND Function: Energizes solenoid with both button activations.
OR Function: Energizes solenoid with either button activation.
NAND Function: Energizes solenoid unless both buttons are activated.
NOR Function: Energizes solenoid unless either button is activated.

Dual Command Circuits
Describes circuits with dual commands for maintenance.

Emergency Control
Discusses emergency control methods for safety.

Figures and Diagrams
Includes figures illustrating circuit configurations.

Overview
Analyzes electro-pneumatic circuits for cylinder control.

Specifications
Outlines solenoid valve use for cylinder movement control.

Procedures
Describes operational procedures for cylinder cycles.

Norms and Recommendations
Emphasizes safety conditions for stroke execution.

Key Diagrams and Equations
Includes figures and equations for sequence control.

Critical Information
Highlights memory circuit use for signal control.

Overview
Outlines electro-pneumatic circuit operation for cylinder strokes.

Specifications
Uses monostable solenoid valves and limit switches for control.

Procedures

Phase 1 (Stroke A+): Initiated by I.C. button for positive stroke.
Phase 2 (Stroke B+): Triggered by contacts for positive stroke.
Phase 3 (Stroke B-): Activated by limit switch for negative stroke.
Phase 4 (Stroke C+): Initiated by limit switch for positive stroke.
Phase 5 (Stroke C-): Triggered by limit switch for negative stroke.
Phase 6 (Stroke A-): Activated by limit switch for negative stroke.

Key Components

Relays: Control sequence of operations.
Solenoids: Control valve positions for strokes.
Limit Switches: Detect cylinder positions.

Recommendations
Ensure correct wiring and maintenance for sequence integrity.

Catalog excerpts

Pneumatic automation from basic principles to practical techniques EN-1

CAMOZZI AUTOMATION PNEUMATIC AUTOMATION CAMOZZI COMPETENCE CENTRE Contacts Camozzi Automation S.p.A. Società Unipersonale Via Eritrea, 20/I 25126 Brescia Italy Tel. +39 030 37921 [email protected] A Camozzi Group Company PNEUMATIC AUTOMATION FROM BASIC PRINCIPLES TO PRACTICAL TECHNIQUES

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Pneumatic automation from basic principles to practical techniques EN-2

Published by Camozzi Automation S.p.A. Società Unipersonale Via Eritrea, 20/I 25126 Brescia Itay Tel. +39 030 37921 [email protected] 2019 Edition All rights reserved. Every intellectual property right on the contents of this manual is reserved for the purposes of the legislation. All the contents of these pages (title, texts, images and drawings included) may not, either totally or in part, be reproduced, published or distributed in any way without the prior written consent.

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Pneumatic automation from basic principles to practical techniques EN-3

CAMOZZI COMPETENCE CENTRE PNEUMATIC AUTOMATION FROM BASIC PRINCIPLES TO PRACTICAL TECHNIQUES

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Pneumatic automation from basic principles to practical techniques EN-4

THE IMPORTANCE OF EDUCATION IN PNEUMATICS Camozzi Competence Centre Expertise and passion Providing innovative high quality solutions to clients, Einstein stated “It is the supreme art of the teacher to offering efficiency, quality and reliability with awaken joy in creative expression and knowledge”. components adapted to the requirements of each It is now even more essential to institute an ongoing sector, thereby resulting in maximum added value training program which includes theoretical in terms of both performance and customer benefit, principles to complement knowledge acquired this has...

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Pneumatic automation from basic principles to practical techniques EN-7

THE UTILIZATION OF PNEUMATIC AUTOMATION IN THE INDUSTRIAL SECTOR Knowledge, imagination, creativity Progress begins here Knowledge is our greatest asset, and when the principles upon which the operation of knowledge, imagination and creativity coalesce, the products and respective applications are based. ideas are born, which stimulate progress and growth. In particular, process automation displays unique The rapidity of technological evolution features within each sector with pneumatics which characterizes this industry, demands representing one of the most common technologies, that component...

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Pneumatic automation from basic principles to practical techniques EN-8

CAMOZZI TECHNOLOGY AND TAILOR-MADE INDUSTRIAL SOLUTIONS Camozzi Automation is one of the leading Camozzi Automation is an international international groups operating in the field of network based in Italy with a presence on all pneumatic components for industrial automation. continents, comprising sales offices and workshops in 21 countries, with exclusive distributors With 6 manufacturing plants, structured according covering over 75 countries. to the principles of “Lean Production”, and supported by MARC (Mechatronic Application Research Center), Continuous technological research, development...

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Pneumatic automation from basic principles to practical techniques EN-10

CAMOZZI AUTOMATION > PNEUMATIC AUTOMATION Index Chapter 1 PHYSICS The air Atmospheric pressure Absolute and relative pressure Boyle’s law The effect of temperature on gases Gay-Lussac’s law Relationship between pressure, volume and temperature Pressure and flow rate Pascal’s principle Venturi’s principle Mechanical concepts Magnetism and electromagnetism Chapter 2 AIR PRODUCTION AND PREPARATION 38 Compressors 40 From the compressor to the air receiver 41 From the receiver tank to the point of use 43 Pipe size calculations 44 Treatment of compressed air: - the filter - coalescing filters 47 Pressure...

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Pneumatic automation from basic principles to practical techniques EN-11

CAMOZZI AUTOMATION > PNEUMATIC AUTOMATION Manual operation of poppet valves Mechanical operation of poppet valves Mini poppet valves 3/2-way spool valves 5/2-way spool valves Manual and mechanical operating devices for spool valves Pneumatic operating devices for the valves Directly operated solenoid valves Servo solenoid valves with internal pilot Servo solenoid valves with external pilot Three-position valves Blocking valves: - unidirectional - bidirectional Double 2/2-way and 3/2-way valves Signal processing valves Nominal flow rate Sizing of directional control distribution valves and connecting...

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Pneumatic automation from basic principles to practical techniques EN-12

CAMOZZI AUTOMATION > PHYSICS

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Pneumatic automation from basic principles to practical techniques EN-13

CAMOZZI AUTOMATION > PHYSICS The air Atmospheric pressure Absolute and relative pressure Boyle’s law The effect of temperature on gases Gay-Lussac’s law Relationship between pressure, volume and temperature Pressure and flow rate Pascal’s principle Venturi’s principle Mechanical concepts Magnetism and electromagnetis

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Pneumatic automation from basic principles to practical techniques EN-14

CAMOZZI AUTOMATION > PHYSICS Every entity having mass and space dimensions is defined matter and is made up of minute particles called “molecules”. Matter exists in the following forms: • solid, the molecules are rigidly bound, consequently the solids take on their own shape and volume; • liquid, the molecules are not rigidly bound together, they possess volume and assume the shape of the container which holds them; • gaseous, the molecules move freely - to the point that the distance between them varies continuously, as does their relative positions. Gases therefore have neither shape nor definitive...

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Pneumatic automation from basic principles to practical techniques EN-15

CAMOZZI AUTOMATION > PHYSICS Atmospheric pressure Air possesses weight as a result of the Earth’s gravity. The sensation of weight exerted on anything it comes into contact with is called atmospheric pressure. One of the characteristics of atmospheric pressure is that it varies according to the altitude. The maximum value is at sea level (zero altitude) and decreases as the altitude increases. This is due to the weight of the air on the lower layers of the atmosphere being greater than the weight on the upper layers. At sea level the atmospheric pressure is an average of 760 mm Hg and decreases...

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Pneumatic automation from basic principles to practical techniques EN-16

CAMOZZI AUTOMATION > PHYSICS The height which the column of water must achieve to equal the atmospheric pressure is 10,3 m. In the International System the unit of measurement of pressure is the Pascal (Pa) and is equal to the pressure of a Force of 1 N over 1 m2. 1 Pa = 1 N ⁄ m2 A much used multiple of Pa is the bar (even though it doesn’t belong to the International System): 1 bar ≈ 100.000 Pa ≈ 0,1 MPa The table below illustrates the most common units of measure: bar mercury column column of water same weight 10,33 Newton Absolute and relative pressure In this chapter we observe the phenomena...

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