Pneumatic Circuit Design

Operating a Single-Acting Pneumatic Cylinder with a Pneumatic Push Button (Using AutoSim 200)

In this project, AutoSim 200 simulation software is used to design and operate a simple pneumatic system. The main goal is to control a single-acting cylinder using a pneumatic push button valve.

Components used:

Single-acting pneumatic cylinder
3/2-way pneumatic push button valve (spring return type)
Air compressor (pressure source)
Air supply lines (pipes)
Working Principle:

In the default position, the 3/2-way push button valve blocks the air flow, and the spring in the single-acting cylinder keeps it retracted.
When the push button is pressed, the valve allows compressed air to flow into the cylinder.
Air pressure pushes the piston out (extends the cylinder).
When the button is released, the valve returns to its normal position (spring return), cutting off the air supply and venting the cylinder.
The internal spring inside the cylinder retracts the piston back automatically.
Steps in AutoSim 200:

Open AutoSim 200 and create a new pneumatic project.
Select and place the air compressor (pressure source).
Insert a 3/2-way push button valve (normally closed, spring return).
Place a single-acting cylinder on the workspace.
Connect the compressor to the valve input port.
Connect the valve output port to the cylinder air inlet.
Connect the valve exhaust port to atmosphere.
Run the simulation.
Press the virtual push button to observe the cylinder extending.
Release the button to observe the cylinder retracting.
Resources
 

Operating a Double-Acting Pneumatic Cylinder with Push Buttons (Using AutoSim 200)

In this exercise, AutoSim 200 software is used to design and simulate a pneumatic circuit that controls a double-acting cylinder with two pneumatic push buttons.

Components used:

Double-acting pneumatic cylinder
Two 3/2-way pneumatic push button valves (spring return type)
5/2-way directional control valve (spring-centered, pneumatically actuated)
Air compressor (pressure source)
Air supply lines (pipes)
Working Principle:

A 5/2-way valve is used to control the double-acting cylinder.
One push button is used to extend the cylinder.
Another push button is used to retract the cylinder.
Pressing the "Extend" button sends a pneumatic signal to shift the 5/2 valve and direct air to the cylinder’s cap end, causing extension.
Pressing the "Retract" button sends a pneumatic signal to shift the 5/2 valve in the opposite direction, causing retraction.
Releasing both buttons allows the 5/2 valve's spring return mechanism to bring it back to a neutral position if designed, or to stay in the last position if it’s a bistable valve (based on selection).
Steps in AutoSim 200:

Open AutoSim 200 and start a new pneumatic project.
Add the air compressor (pressure source).
Place a 5/2-way directional control valve (spring-centered or bistable).
Place a double-acting pneumatic cylinder.
Insert two 3/2-way pneumatic push button valves (spring return).
Connect:

The compressor to the pressure input of the 5/2 valve.
The cylinder ports (A and B) to the 5/2 valve outlets.
One push button to control extension (first pilot port of the 5/2 valve).
The other push button to control retraction (second pilot port).
Connect exhaust ports to the atmosphere.
Simulate the circuit.
Press "Extend" push button to extend the cylinder.
Press "Retract" push button to retract the cylinder.

Series Connection in Pneumatics

Series connection means components are connected one after another in such a way that the operation of one affects the next.
In pneumatics, this often involves:

Multiple valves connected in a sequence
Sensors and actuators depending on previous actions
Common example: A cylinder extends only after a sensor is activated.
?️ How to Create a Series Connection in AutoSim 200

Open AutoSim 200 and start a New Project.
Insert Components:

Drag and drop valves, cylinders, sensors.
Example: 2 push buttons + 1 solenoid valve + 1 cylinder.
Connect Components Sequentially:

Wire the push buttons in series (output of Button 1 to input of Button 2).
Then connect the output to the solenoid valve.
The valve controls the cylinder extension.
Simulation:

Both buttons must be pressed (series condition) for the cylinder to activate.

Create the Pneumatic Circuit:

From the library, drag and drop the following:

FRL unit (Filter-Regulator-Lubricator)
5/2 Way Double Solenoid Valve
Double Acting Cylinder
Connect:

Air source → FRL → Port P of the 5/2 valve.
Port A → Cylinder cap-end (for extension / door opening).
Port B → Cylinder rod-end (for retraction / door closing).
2. Add Electrical Components:

From the electrical library, drag:

4 Pushbuttons (NO type):

Inside Start
Inside Stop
Outside Start
Outside Stop
2 Solenoids:

Solenoid A (for door opening)
Solenoid B (for door closing)
Connect:

Inside Start + Outside Start → Solenoid A
Inside Stop + Outside Stop → Solenoid B
Tip: Use parallel wiring for inside and outside buttons, so either inside or outside can operate it.

3. Programming (if needed):

No special programming is required if you directly wire push buttons to solenoids.
But, if you want memory latching (e.g., door stays open until stop button pressed), you can create a basic relay logic using Set/Reset (Latch/Unlatch) contacts.
4. Simulation:

Press the Start simulation button
Now, press Inside Start:

Solenoid A energies, the 5/2 valve shifts, cylinder extends → Door Opens.
Press Outside Stop:

Solenoid B energizes, the 5/2 valve shifts back, cylinder retracts → Door Closes.
Test from both inside and outside!
? Visual in AutoSIM-200:

You will see:

Pneumatic circuit on the top
Electrical circuit (push buttons + solenoids) at the bottom
Live animation: Cylinder moving, valve switching, and lights on push-buttons showing activation.

Air Source → Compressed air connected through a Filter-Regulator-Lubricator (FRL) unit.

Cylinder A → Double-acting cylinder.

Cylinder B → Double-acting cylinder.

 Directional Control Valves (DCVs):

One 5/2 way single solenoid valve for Cylinder A.
One 5/2 way single solenoid valve for Cylinder B.
? Pushbuttons (Manual air-operated valves):

Good Pushbutton → Directs air to operate only Cylinder A's valve (Cylinder A forward, Cylinder B stays retracted).
Reject Pushbutton → Vents air from both Cylinder A and Cylinder B (both cylinders retract).
Rework Pushbutton → Directs air to operate both Cylinder A and Cylinder B valves (both cylinders forward).
? Valve Functionality:

When the Good button is pressed: Air flows to Cylinder A → Cylinder A extends; Cylinder B remains idle.
When the Reject button is pressed: Air supply to both cylinders is cut → Both cylinders retract.
When the Rework button is pressed: Air flows to both Cylinder A and Cylinder B → Both cylinders extend.
 Exhaust Lines:

Both directional valves have exhaust ports connected to silencers.
Resources

Basic Concept:

When a start signal is given, the cylinder extends to open the door.
When it reaches the fully open position, detected by a limit switch (LS1), it automatically retracts to close the door.
When it reaches the fully closed position, detected by another limit switch (LS2), it waits for the next start.
Components Needed in AutoSim 200:

1 Double-Acting Cylinder
1 5/2 Solenoid Valve (single coil or double coil type)
2 Limit Switches (LS1 = Open position, LS2 = Closed position)
1 Start Push Button (or you can simulate it with a sensor or manual switch)
Optional: Timer (if you want slight delays)
Logical Sequence:

Press Start → energize Solenoid A → Cylinder extends.
When cylinder is fully extended → LS1 activated.
LS1 triggers → de-energizes Solenoid A, energizes Solenoid B → Cylinder retracts.
When cylinder is fully retracted → LS2 activated → system resets, ready for next start.
Simple Step-by-Step in AutoSim 200:

Place Cylinder: Select a double-acting cylinder.
Place 5/2 Valve: Controlled by two solenoids (A for extend, B for retract).
Connect Limit Switches:

LS1 detects extended position.
LS2 detects retracted position.
Electrical Circuit:

Start Button energizes Solenoid A.
LS1 switches control from Solenoid A to Solenoid B.
LS2 stops Solenoid B and resets.
Air Supply: Connect an air compressor/source.
Resources
 

Pneumatic Circuit for Sequential Operation of Two Cylinders:

Components:

Cylinder A (Double-acting)
Cylinder B (Double-acting)
2 x 3/2 NC Solenoid Valves (for each cylinder)
2 x Limit Switches (for detecting extended positions of cylinders)
1 x Push Button (for initiating the sequence)
1 x Pneumatic Relay or 5/2 Valve (to control the sequence)
Step-by-Step Description:

Start Sequence:

When the start button is pressed, the push button valve (or an external switch) activates, energizing the solenoid valve for Cylinder A.
Cylinder A Extends:

The solenoid valve for Cylinder A (connected to a 3/2 NC valve) opens, allowing air to extend Cylinder A.
Limit switch A detects when Cylinder A is fully extended and sends a signal to the control system to proceed to the next step.
Cylinder B Extends:

Once Cylinder A is fully extended (sensor A), the signal is sent to activate the solenoid valve for Cylinder B.
Cylinder B extends as air flows through its valve.
Cylinder B Retracts:

Once Cylinder B is fully extended, it sends a signal via its limit switch B to retract.
The solenoid valve for Cylinder B de-energizes, causing Cylinder B to retract.
Cylinder A Retracts:

Once Cylinder B has retracted (limit switch B detects), the system sends a signal to retract Cylinder A.
The solenoid valve for Cylinder A de-energizes, causing it to retract.
Cycle Restarts:

Once both cylinders are retracted, the cycle can start over when the push button is pressed again.
Resources.