INDUSTRIAL PNEUMATIC SYSTEMS

CONTENTS

1. What is Industrial pneumatics?
2. Components of Industrial pneumatic systems
3. Applications for industrial pneumatics
4. Advantages of pneumatic systems
5. Pneumatics or hydraulics?
6. History of the development of pneumatics
7. Conclusion

Pneumatics offer several benefits that make them widely used in various applications. These benefits make pneumatics a preferred choice in various industries where efficiency, safety, and reliability are paramount.

• Simple Design: Pneumatic systems have a straightforward design, making them easy to understand and maintain. Control of pneumatic devices is often simpler and more intuitive than electronic or hydraulic systems.
• Cost-Effective: Pneumatic components are generally less expensive than hydraulic or electric components. The simplicity of pneumatic systems also contributes to lower maintenance costs.
• Safety: Pneumatic systems are inherently safer in certain environments, especially in in hazardous environments situations where there is a risk of explosion since they don’t generate sparks and are less likely to cause fires.
• Reliability: Pneumatic systems are known for their reliability and durability, with minimal maintenance requirements. They can operate in harsh conditions and withstand extreme temperatures without significant loss of performance.
• Clean Operation: Pneumatic systems do not produce contaminants during operation, making them suitable for environments where cleanliness is crucial, such as in the food and pharmaceutical industries.
• Fast Response Time: Pneumatic systems can respond quickly to control signals, making them suitable for applications where rapid movements or reactions are necessary.
• Versatility: Pneumatic systems can perform a wide range of tasks, from simple linear movements to complex automation processes. They are versatile and adaptable to different applications.
• Ease of Installation: Installing pneumatic systems is generally quicker and easier compared to some other power transmission systems. This can lead to reduced downtime during setup.
• Powerful and Lightweight: Pneumatic systems can deliver a significant amount of power relative to their size and weight. This is particularly advantageous in applications where space and weight are critical factors.
• Energy Efficiency: Pneumatic systems can be energy-efficient, especially when designed with proper controls. They only consume energy when in use, and there is minimal energy loss in the transmission process.

Despite these advantages, it’s important to note that pneumatic systems also have limitations, such as lower power density compared to hydraulic systems and limited speed control in some applications. When specific speeds are needed, additional devices must be attached to the pneumatic system to procure the desired result. Pneumatic systems are sometimes less durable that hydraulic counterparts since moisture accumulation the system can freeze up. The choice of a power transmission system depends on the specific requirements of the application.

Pneumatic systems use air and gasses while hydraulic systems use fluids to move force and energy through machines. Both are well suited to making machines reciprocate and rotate and can operate at considerable distances from their compressor or pump without any need for things like conveyor belts or gears. Both can achieve considerable power with relatively lightweight machines. So, if both types of systems do similar jobs, why would you use a pneumatic machine instead of a hydraulic one, or use either of these in place of something electric? There are many different factors to consider.

• Power: For medium-power, high-speed, applications where accuracy isn’t critical, and soft action or cushioning (force absorbing) are important, pneumatic systems are often preferred to hydraulic ones. Hydraulics tends to win for high power, high accuracy, high force transmitting applications, and any application where variations in air temperature or pressure might cause problems for a pneumatic system. But hydraulic machines do tend to move more slowly. A bigger machine, like a crane or bulldozer, is much more likely to be hydraulic
• Speed and accuracy: Pneumatic machines are generally, but not always, less responsive and less accurate than hydraulic ones, largely due to the compressibility and relative unpredictability of air. Pneumatic machines tend to be faster than hydraulic ones.
• Convenience: Pneumatic systems use lower pressure and smaller forces than hydraulic systems, so they tend to be lighter and more compact, which can be extremely important in the case of things like hand tools or other applications where weight is an issue. Pneumatics can be made of relatively light plastic, whereas hydraulic ones must be made from metals to cope with higher forces and pressures.
• Safety: Leakage is a potential problem in both hydraulic and pneumatic systems. While pneumatic tools and machines invariably exhaust their working gas to the air once it’s expanded and done its job, hydraulic ones are sealed units designed to keep the same fluid recirculating. Since hydraulic fluid is flammable, pneumatic systems are inherently much safer than hydraulic ones in dangerously explosive environments.
• Practical Operation: Since hydraulic machines use oil, they are self-lubricating and often much quieter than pneumatic tools which don’t self-lubricate. The compressors and exhausts of pneumatic tools can be especially noisy, although silencers and other noise reduction equipment can be fitted.

The history of industrial pneumatic systems spans centuries, with roots in ancient civilizations and gradual advancements leading to the development of sophisticated pneumatic systems. Here’s a brief overview of the history of pneumatics:

• Ancient Origins: The origins of pneumatics can be traced back to ancient Greece. Scholars like Hero of Alexandria (circa 10-70 AD) conducted experiments involving air and steam, laying the foundation for early pneumatic principles. Hero’s inventions, such as the aeolipile, demonstrated basic concepts of steam and air power. During the Middle Ages leather bellows were invented for blacksmiths to make fire more efficient and were later used as a source of pneumatic power in things like organs.
• 17th Century: In 1643, Italian physicist Evangelista Torricelli invented the mercury barometer, contributing to the understanding of air pressure. Torricelli’s work set the stage for the exploration of gases and the principles underlying pneumatics. In 1654, German physicist Otto von Guericke develops the vacuum pump. Famously, he demonstrates its power by pumping the air from in between two huge hemispheres. Atmospheric air pressure clamps the spheres together so firmly that teams of horses cannot pull them apart.
• 18th Century: Daniel Bernoulli, a Swiss mathematician and physicist, formulated Bernoulli’s principle in the 18th century. This principle explained the relationship between the speed of a fluid (including air) and its pressure, providing fundamental insights into fluid dynamics, crucial for pneumatics. In 1700 Frenchman Denis Papin used a waterwheel to compress air and pipe it to a machine. His work on pressurized gases helps others to develop the steam engine and the diving bell. In 1799, Scottish engineer William Murdoch first proposed the idea of pneumatic tube transport and in 1799, British engineer George Medhurst proposed an early pneumatic (“atmospheric”) railway powered by air pressure instead of steam, including the idea of using compressed air to power a motor (a device he calls an aeolian engine).
• 19th century: With the coming of the Industrial Revolution, and advancements in pneumatic technology paralleled developments in industry. Engineers began developing practical pneumatic devices for industrial applications, and compressed air started being used in various machines. In 1847, Mechanics Magazine summarizes his idea as “a new method of driving carriages of all kinds without the use of horses, by means of an improved aeolian engine, and which engine may also be applied to various other useful purposes (the power applied to the machinery being compressed air, and the power to compress the air being generally obtained by wind, etc. Then in 1865, British inventor George Law developed the pneumatic rock drill, in which compressed air pumping a piston bangs a hammer into the ground. The following year, a four-cylinder drill is used to dig the Hoosac tunnel in Massachusetts, USA. In 1869, US industrial engineer George Westinghouse is granted a patent (US patent #88,929) for a pneumatic steam railroad brake. In 1879, while developing better methods for carrying cash around buildings, US inventor William Stickney Lamson revives William Murdoch’s pneumatic tube transport idea, now known as the Lamson tube.  Other notable inventors, such as George Medhurst, also contributed to the understanding and development of pneumatic power for industrial purposes.
• 20th Century: Pneumatic technology gained traction in the early 20th centuries, with applications in transportation and industry. The development of pneumatic tools, including drills and riveters, became integral to construction and manufacturing processes. Pneumatic power was explored in early transportation systems, such as trams and trains. Pneumatic technology played a vital role in various military applications during World War II. Aircraft systems relied on pneumatic components. After World War II, the application of pneumatics expanded significantly, particularly in industrial automation. Pneumatic systems became crucial for control mechanisms, automated processes, and various manufacturing applications. Components such as valves, actuators, and air compressors were developed to enhance the efficiency and reliability of pneumatic systems.
• Contemporary Era: In the contemporary era, pneumatics remains an essential part of industrial automation, robotics, and various technological applications. Advanced materials, electronic control systems, and energy-efficient designs have further improved the capabilities of pneumatic systems. In 2013, US inventor Elon Musk began work on his Hyperloop, a mass-transit people carrier based on giant pneumatic tubes, not unlike Lamson tubes. Today, pneumatic systems are widely used in manufacturing, automotive, aerospace, and other industries, providing reliable and cost-effective solutions for a range of applications. The historical evolution of pneumatics reflects a continuous journey of discovery, innovation, and practical implementation.