Pneumatic products and Their Function — The Building Blocks of Industrial Automation

Introduction

In the field of modern industrial automation, pneumatic technology is widely used in various automation equipment and systems due to its advantages of fast response speed, simple structure, relatively low cost, and easy maintenance.

Pneumatic technology is not only suitable for small and medium-sized load applications, but also demonstrates increasingly strong vitality in new industries such as food, medicine, electronics, and packaging due to its clean, safe, and environmentally friendly characteristics.

An efficient and stable pneumatic system relies on the rational combination and scientific selection of various pneumatic components. From gas source processing, directional control to execution units, each type of component has its own clear functional positioning

When selecting equipment, integrating systems, or diagnosing faults, engineers must have a deep understanding of the functions of various pneumatic components and their roles in the system in order to achieve optimal design and operational results.

To help you understand the composition and working principle of pneumatic systems more systematically, this article will introduce six common types of pneumatic components and provide detailed information on the roles each component plays in pneumatic systems.

Air Compressor

The air compressor is typically located at the front end of a pneumatic system, followed by the air storage tank and air treatment unit. Only compressed and purified air can enter the control system and actuators, ensuring efficient operation of the pneumatic equipment and extending its service life.

As the power source of the pneumatic system, the main function of the air compressor is to compress atmospheric air into high-pressure air, store it in the air tank, or deliver it through pipelines to various parts of the pneumatic system, providing a continuous and stable energy source for actuators such as cylinders and valves.

To ensure proper and effective use of the air compressor and to avoid future maintenance costs, the following operating procedures and precautions should be followed:

Operating Instructions:

• Check whether the lubricating oil is sufficient;

• Ensure the power connection is secure;

• Check that the exhaust valve and drain valve are closed;

• Start the compressor in unloaded mode and wait until it runs smoothly before loading;

• Set the pressure range; the common pressure range for pneumatic systems is 0.5–0.8 MPa;

• Monitor pressure gauge, ammeter, and temperature gauge;

• Drain water regularly to prevent corrosion caused by water accumulation;

• After unloading, cut off the power and record drainage and maintenance activities.

Precautions During Operation:

• Air cleanliness: Air with impurities will affect the service life of pneumatic components. Use a filter-regulator-lubricator (FRL) unit to filter, regulate, and lubricate the air.

• Pipeline layout: Design pipelines to be as short and straight as possible to minimize pressure loss and air leakage.

• Pipe diameter selection: Select pipe diameters appropriate to the pressure range to avoid pressure instability.

• Air tank capacity: The capacity should match the system's air consumption, typically 6–10 times the total exhaust volume.

• Compressed air pressure: Must not exceed the minimum rated pressure of any pneumatic component.

Moreover:

• It is recommended to use compressors or air tanks with automatic drainage functions;

• Regularly maintain the compressor;

• For high-demand applications, oil-free compressors and precision filtration equipment should be used.

Air Treatment Units

Air source treatment components are commonly referred to as FRL units (Filter, Regulator, Lubricator), and are responsible for purifying compressed air. They are typically installed between the air compressor and pneumatic actuators. These three components are usually integrated into a single module for convenient installation and maintenance. Each of the components performs a distinct and essential function:

Filter

Equipped with an internal filter element and drainage device, the filter removes solid particles and liquid water as the air passes through. This process eliminates moisture, dust, and other contaminants from compressed air, protecting downstream pneumatic components.

Regulator

The regulator adjusts outlet pressure via an internal spring and diaphragm mechanism, ensuring the compressed air is regulated to a stable working pressure required by the system. This guarantees safe and efficient operation.

Lubricator

The lubricator atomizes lubricating oil through a nozzle and mixes it evenly into the airflow, providing necessary lubrication to pneumatic components. This reduces friction and wear, thereby extending equipment life.

These components are not only used in pneumatic systems but also offer advantages in spray painting equipment, food processing industries, and other applications.

Precautions:

• Regularly check and replace the filter element to prevent clogging, which may lead to pressure drops or degraded air quality;

• Adjust the pressure regulator to the appropriate operating pressure range to avoid excessive or insufficient pressure;

• Refill lubricating oil regularly to prevent dry friction, which can cause damage to cylinders or valves;

• Select suitable filtration grades and lubricant types based on the working environment;

• Purchase from qualified pneumatic product manufacturers who offer stable and reliable product quality, as well as pre-sales support and technical services.