Fundamentals of Fluid Power

Part 2: Pneumatics

Components 1
Compressors and Drives

Hubertus Murrenhoff, Olivier Reinertz

15.01.2015
Mobile and Stationary Compressor

Source: Bauer

Compressors and Drives fig. 3.1-1 1 of 83

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Design of Compressors

Compressors and Drives fig. 3.1-2 2 of 83

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Theoretical Compression Process

Compressors and Drives fig. 3.1-3 3 of 83

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Reduction of Compression Work by Two Stage Compression

isothermal compression
(ideal compression process)
pressure p

isentropic compression
second
stage saved work by two stage
compression

first
stage

volume V

Compressors and Drives fig. 3.1-4 4 of 83

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Three Stage Piston Compressor

Compressors and Drives fig. 3.1-5 5 of 83

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Diaphragm Compressor

outlet valves inlet

diaphragm

eccentric cam

Source: KNF Neuberger

Compressors and Drives fig. 3.1-6 6 of 83

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Diaphragm Compressor

 electromechanical  hydraulic

Source: LEWA Herbert Ott Source: LEWA Herbert Ott

Compressors and Drives fig. 3.1-7 and 7 of 83

Murrenhoff, Reinertz fig. 3.1-8
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Vane Compressor

Source: Mannesmann Demag Verdichter

Compressors and Drives fig. 3.1-9 8 of 83

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Fluid Ring Compressor

Source: nash-elmo Industries

Compressors and Drives fig. 3.1-10 9 of 83

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Section View of Screw Compressor Using Synchronous Gear

Source: CompAir

Compressors and Drives fig. 3.1-11 10 of 83

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Compression Process of Screw Compressor

1 2

suction side discharge side

3 4

Source: Boge

Compressors and Drives fig. 3.1-12 11 of 83

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Functional Principle of a Scroll Compressor

suction side

discharge side

Source: Atlas-Copco

Compressors and Drives fig. 3.1-13 12 of 83

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Section View of a Scroll Compressor

Source: Atlas-Copco

Compressors and Drives fig. 3.1-14 13 of 83

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Rotary Tooth Compressor

suction side

discharge side

Source: Atlas-Copco

Compressors and Drives fig. 3.1-15 14 of 83

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Roots Compressor

Source: Aerzener Maschinenfabrik

Compressors and Drives fig. 3.1-16 15 of 83

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Cross Section of a Three Stage Radial Compressor

Source: Atlas-Copco

Compressors and Drives fig. 3.1-17 16 of 83

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Operating Range of Different Compressor Designs

Compressors and Drives fig. 3.1-18 17 of 83

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Control of Compressors

Compressors and Drives fig. 3.1-19 18 of 83

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Discontinuous Control (on-off control with loaded/unloaded start up)

Compressors and Drives fig. 3.1-20 19 of 83

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Discontinuous Control (intermittent control)

Compressors and Drives fig. 3.1-21 20 of 83

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Suction Throttling

Compressors and Drives fig. 3.1-22 21 of 83

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Blow-off Control

Compressors and Drives fig. 3.1-23 22 of 83

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Cascaded Control

Compressors and Drives fig. 3.1-24 23 of 83

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Overview of Pneumatic Drive Designs

Drives
Linear motion Rotary motion
• simple-acting cylinder • rotary drives
- piston rod cylinder - axial piston motor
- diaphragm cylinder - radial piston motor
- bellows cylinder - vane motor
- gear motor
• double-acting cylinder
- turbine
- single-ended piston rod
- double-ended piston rod • semi-rotary drives
- without piston rod - rotary vane cylinder
slotted cylinder - rotary cylinder
magnetic cylinder - swivel motor
wire rope cylinder - rotary belt motor
belt cylinder - stepper drive
• multi-position cylinder
• tandem cylinder
• telescopic cylinder
• impact cylinder

Compressors and Drives tab. 3.2-1 24 of 83

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Components of a Simple-Acting Piston Rod Cylinder

Compressors and Drives fig. 3.2-1 25 of 83

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Possible Assembly of Piston Rod Cylinders

6
2

11 5 1

Compressors and Drives fig. 3.2-2 26 of 83

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Profile variants for Extruded Cylinder Tubes

Compressors and Drives fig. 3.2-3 27 of 83

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Diaphragm Cylinder

Symbol:

Source: EFFBE

Compressors and Drives fig. 3.2-4 28 of 83

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Rolling Diaphragm Cylinder

Symbol:

Source: EFFBE

Compressors and Drives fig. 3.2-5 29 of 83

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Rolling Diaphragm Cylinder for Clamping

Source: Festo

Compressors and Drives fig. 3.2-6 30 of 83

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Compact Cylinder with anti-twist Protection

Source: IMI-Norgren

Compressors and Drives fig. 3.2-7 31 of 83

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Bellows Cylinder

supply port
sub base

multilayer bellow

Compressors and Drives fig. 3.2-8 32 of 83

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Structure of a Double-Acting Piston Rod Cylinder

pressure supply port pressure supply port

piston rod seal cylinder tube

piston rod

connecting thread
guiding bush piston

piston seal end cap

end cap

Source: Festo

Compressors and Drives fig. 3.2-9 33 of 83

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Double-Acting Cylinder with Double-Ended Piston Rod

Source: Hoerbiger Origa

Compressors and Drives fig. 3.2-10 34 of 83

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Rodless Cylinder Designs

a. sliding seal (slotted) cylinder c. rope cylinder

b. magnetic cylinder d. belt cylinder

Compressors and Drives fig. 3.2-11 35 of 83

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Design of a Slotted Cylinder without Piston Rod

slide

sliding seal
locking for
sealing strip

piston

outer sealing strip

with seal

cap with pressure end position damping

supply port

Compressors and Drives fig. 3.2-12 36 of 83

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Rodless Cylinder with Traction Mechanism

slide with adjustable guide

air lead through

elliptic traction mechanism
elliptic cylinder bore

Source: Rexroth Pneumatik

Compressors and Drives fig. 3.2-13 37 of 83

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Rodless Cylinder – Magnetic Link

slide set of permanent magnets pneumatic damping connection cap

magnets for housing of a thin

piston
end–position detection completely closed tube

Source: Festo

Compressors and Drives fig. 3.2-13 38 of 83

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Schematic of a Multi-Position Cylinder

Compressors and Drives fig. 3.2-14 39 of 83

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Multi-Position Cylinder with adjustable switchable Stops

1 2 3 4 5

Compressors and Drives fig. 3.2-15 40 of 83

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Tandem Cylinder Schematic

Symbol:

Compressors and Drives fig. 3.2-16 41 of 83

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Telescopic Cylinder Schematic

Symbol:

Compressors and Drives fig. 3.2-17 42 of 83

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Flat Cylinder with Reed-Detecters

Source: Rexroth Pneumatik

Compressors and Drives fig. 3.2-18 43 of 83

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Cylinder Design with double Piston Rods

Source: Hoerbiger Origa

Compressors and Drives fig. 3.2-19 a 44 of 83

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Pneumatic Linear Module

Source: Rexroth Pneumatik

Compressors and Drives fig. 3.2-19 b 45 of 83

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Cylinder with Integrated Linear Guide

Source: Numatics

Compressors and Drives fig. 3.2-20 46 of 83

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Pneumatic Compact Carriage

Source: SMC

Compressors and Drives fig. 3.2-21 47 of 83

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Pneumatic Muscle

Source: Festo

Compressors and Drives fig. 3.2-22 48 of 83

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Muscle Dynamics

Source: Festo

Compressors and Drives extending fig. 3.2-22 49 of 83

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Muscle Dynamics

Source: Festo

Compressors and Drives extending fig. 3.2-22 50 of 83

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Cross Section of a Brake with Eccentric Cam

piston
adjustment of spring
spring preload
eccentric coupling lever
cam

piston rod

Source: Bosch

Compressors and Drives fig. 3.2-24 51 of 83

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Cross Section of a Brake with Clamps

Source: Festo

Compressors and Drives fig. 3.2-25 52 of 83

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Schematic of a Brake with Tilting Plates

Source: Hoerbiger Origa

Compressors and Drives fig. 3.2-26 53 of 83

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Control of a Pneumatic Hammer by a Reversing Valve

R2 R1

tool reversing valve

Compressors and Drives fig. 3.2-27 54 of 83

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Parameters of a Loaded Single-Acting Cylinder


α

g ∙
FFLast
load

m
ccFF
x, x. ..
FFReibung ,x
friction

AAKK Ersatzwiderstand
equivalent resistance
ppAA

Compressors and Drives fig. 3.2-28 55 of 83

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Speed of a Single-Acting Cylinder

Discharge function

extending: ∙ ∙ ∙ , ∙
∙
retracting: ∙ ∙ , ∙ 2

Flow rate characteristic

,
extending: ∙ ∙ ∙ ∙

,
retracting: ∙ ∙ ∙ ∙

Compressors and Drives extending section 56 of 83

Murrenhoff, Reinertz 3.2.1.2.3

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Parameters of a Loaded Double-Acting Cylinder

α

g
FFLast
load

AASS m
ppBB
x, x. ..
F
FReibung ,x
friction

AAKK
ppAA

equivalent resistance
Ersatzwiderstände

Compressors and Drives fig. 3.2-29 57 of 83

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Allowed Piston Rod Length for Buckling Loads

cylinder diameter
max. stroke

rod diameter
pressure

Compressors and Drives fig. 3.2-30 58 of 83

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Qualitative Presentation of the Drive Characteristic for a Symmetrical
Double-Acting Cylinder

Load characteristics for low newtonian friction

Load characteristics for high newtonian friction
Load characteristics for constant weight

Operating status with supercritical valve flow in

outlet

Operating status with subcritical supply and drain

flow

Operating status with maximum output

Compressors and Drives fig. 3.2-31 59 of 83

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Schematic of a Pneumatic End of Stroke Cushioning

Start from
end-position:

Approaching
end-position:

Compressors and Drives fig. 3.2-32 60 of 83

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Double-Acting Cylinder with End of Stroke Cushioning on Both Sides

Symbol:
throttling port
Drosselbohrung damping piston
Dämpferkolben

damping
Dämpfungs-
bore
buchse

Compressors and Drives fig. 3.2-33 61 of 83

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Speed Dependent Friction of a Pneumatic Cylinder

Friction force

Speed

Compressors and Drives fig. 3.2-34 62 of 83

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Circuit- and Start-Up Performance with Upstream Throttling for Check
Valves

cylinder stroke
time t

Compressors and Drives fig. 3.2-35 63 of 83

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Circuit- and Start-Up Performance with Downstream Throttling for Check
Valves

cylinder stroke
time t

Compressors and Drives fig. 3.2-36 64 of 83

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Hydropneumatic Feed Drive

check valve safety valve

flow
control
valve

hydraulic cylinder check valve pneumatic cylinder

Source: Norgren

Compressors and Drives fig. 3.2-37 65 of 83

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Designs of Pneumatic Motors and Power Density of Different Motor
Designs in Comparison

Rotatory Motors Piston Motors Turbine Motors

Vane motor Axial piston motor Axial turbine

Gear motor Radial piston motor Radial turbine
Roots motor

Power / Weight Power / Volume

Type of Motor [W / kg] Comparison [W / dm3] Comparison
Factor Factor
compressed air vane motors 300 1 1000-1200 1
compressed air piston motors 70-150 0,4 70-300 0,2
hydraulic motors 600-800 2,5 2000 1,7
electric motor 20-100 0,2 70-150 0,1
diesel motors 70-150 0,4 20-70 0,03
 

Compressors and Drives tab. 3.2-3 / 3.2-4 66 of 83

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Designs of Reversible Vane Motors

exhaust duct air duct exhaust duct air duct

vane vane

rotor rotor

stator stator

extra exhaust duct

a) two ports b) three ports

Compressors and Drives fig. 3.2-38 67 of 83

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Technical Work of a Pneumatic Motor with (a, 1, 2, b) and
without (a, 1, 2, b) the Use of Expansion Work

Compressors and Drives fig. 3.2-39 68 of 83

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Gear Motor

exhaust

Compressors and Drives fig. 3.2-40 69 of 83

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Piston Motor

Compressors and Drives fig. 3.2-41 70 of 83

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Radial Piston Motor

control shaft

control ring

rotor

working piston

cam disk

Source: BIBUS GmbH

Compressors and Drives fig. 3.2-42 71 of 83

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Characteristics of Power and Torque for Pneumatic Motors

nN : Nominal speed
n0 : Idling speed
PN : Nominal power
torque

MN: Nominal torque

MA: Starting torque
MW: Stalling torque

speed

Compressors and Drives fig. 3.2-43 72 of 83

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Qualitative Comparison of Flow and Mass Flow Rate of Cylinder and
Rotary Drives

Cylinder: Motor:

Compressors and Drives fig. 3.2-44 73 of 83

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Characteristics of Pneumatic Motors

norm m³/rotation

displacement as nominal volume in litres

Rotary speed Md
nominal pressure pn rotations n

Gear motors Axial piston motors

Radial piston motors Vane motors

Compressors and Drives fig. 3.2-45 74 of 83

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Centrifugal Force Controller and Characteristics of a Controlled Motor

Compressors and Drives fig. 3.2-46 75 of 83

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Example of an Electro-Pneumatic Speed Control

controller

Compressors and Drives fig. 3.2-47 76 of 83

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Temperature vs. Rotational Speed for Pneumatic Motors

inlet
temperature
temperature ϑ

temperature ϑ
Rotary speed n Rotary speed n

exhaust
temperature

p1 = 3bar p1 = 5bar

Compressors and Drives fig. 3.2-48 77 of 83

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Icing Area in the Characteristics of a Pneumatic Motor

icing
limit
torque M

power P
rotational speed n rotational speed n

Compressors and Drives fig. 3.2-49 78 of 83

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Schematic of a Semi-Rotary Drive with a Linear Cylinder

Compressors and Drives fig. 3.2-50 79 of 83

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Semi-Rotary Vane Drive

Source: Festo

Compressors and Drives fig. 3.2-51 80 of 83

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Cut View of a Semi-Rotary Drive

Source: ECKART GmbH

Compressors and Drives fig. 3.2-52 81 of 83

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Semi-Rotary Drive with Toothed Belt

housing

toothed belt
chamber
A
pinion
chamber
B

Source: G.A.S. GmbH

Compressors and Drives fig. 3.2-53 82 of 83

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Pneumatic Stepper Motor

piston 1
detent plate

piston 2

piston 3

wobbling plate

Source: Bibus AG

Compressors and Drives fig. 3.2-54 83 of 83

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 Thank you very much
for your attention.

Questions & suggestions?

Hubertus Murrenhoff
24.07.2013