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Pressure Regulating Valve
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A Pressure regulating valve provides a
relatively constant pressure by reduces the input pressure of a fluid to a
desired value at its output. Regulators are used for gases and liquids.
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Introduction
Air pressure which is too low is
uneconomical because it results in poor efficiency. This is why it is
necessary to take pressure at the optimum operating level by means of a
pressure regulating valve. This level will depend on the type of pneumatic
device used.
There are two types of regulators:
1.
Standard Regulators, and
2.
Pilot Operated Regulators
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Standard Regulator
Outlet pressure is set by the adjusting
screw loading the setting spring to hold the main valve open, allowing flow
from the P1 inlet port to the P2 outlet port. Outlet pressure can be
balanced against the spring adjustable force using a piston or a diaphragm.
Then the pressure in the circuit
connected to the outlet rises and acts on the diaphragm, creating a lifting
force against the spring load.
If the consumption rate decreases, P2
will slightly increase; this increases tile force on the diaphragm; diaphragm
elevates; and air flow decreases until it matches the consumption rate and
the output pressure is maintained.
If the consumption level increases, P2
will slightly decrease, force on the diaphragm decreases; diaphragm descends;
and air flow increases until the consumption is balanced.
With no air consumption, the valve is
closed.
If exit pressure rises above the set
value (exit pressure is regulated at a lower level, otherwise there will be a
pressure peak at the pneumatic actuator), tile diaphragm will lift to open
the relieving seat so that excess pressure can be bled off through the vent hole
in the regulator body.
With very high flow rates, the valve is
wide open.
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Pilot Operated Regulator
The operation is similar to a standard
pressure regulator, but the pilot operated regulator offers a higher accuracy
of pressure regulation.
This higher accuracy is obtained by
replacing the setting spring of a standard regulator with pilot pressure from
a small pilot regulator sited on the unit.
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Filter Regulating Unit
Air filtering and pressure regulation are
combined in the single filter regulator, which provides a compact space
saving unit.
FILTERING
Atmospheric
air has dust and humidity. After the compression, humidity condenses in the
after-cooler and in the air receiver, but there are always some rests, apart
from oil and wear from the sealing.
In order
to remove these polluting agents, it is necessary to clean the air in the
closest part to the operation area, that is why filters are used.
There are
different kinds of filters
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Standard Filter
The standard filter is a combined water separator
and filter. If the air has not been de-hydrated beforehand, a considerable
quantity of water will be collected and the filter will hold back solid
impurities as dust and rust particles.
The separation of water, oil and other
heavy particles occurs by a rapid rotation of the air, caused by the
deflector at the inlet. These particles crash on the wall of the filter bowl
before running down to collect at the bottom. Then they can be drained off
by means of a manual or automatic drain.
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Micro-Filter
Micro-filters are used when contamination
by oil vapour is undesirable. The air flows from the inlet to the centre of
the filter carriage ridge then outwards through the outlet. Dust is trapped
within the micro- filter element, the oil vapour and water mist is converted
into liquid, falling to the bottom of the bowl induced by a coalescing action
inside the filter material.
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Sub- Micro Filters
Sub-micro filters virtually eliminates
oil, water and fine particles down to 0.01 of a micron, to provide maximum
protection to pneumatic devices such as measuring devices, spray painting,
electrostatic devices, cleaning and drying of electronic accessories. These filters
have additional layers which provide higher filtration efficiency.
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Air Quality
There are
7 typical degrees of Filtration:
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Typical applications for the 7 filtering levels are:
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Sizing of Regulators and Filters
It is important in order to get the
desired flow for a particular application, with a minimum pressure variation
in all the unit's flow range, depending on two factors:
1.
The maximum flow used, and
2.
The maximum acceptable pressure drop.
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Compressed Air Lubrications
Lubrication is no longer a necessity for
the majority of modern Pneumatic components, most are pre-lubricated for
life.
This provides some advantages such as:
- Savings (there is no need to purchase a lubrication device).
- Cleaner and more hygienic systems.
- Oil-free atmosphere for a healthier, safer working environment).
Certain equipment still requires
lubrication. To ensure they are continually lubricated, a certain quantity
of oil is added to the compressed air by means of a lubricator.
Basically, there are four kinds of
lubricators:
1.
Proportional
2.
Injection
3.
Micro Mist
4.
Centralized Systems
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Proportional Lubricators
A flow- proportional pressure drop is
provoked between inlet and outlet. This makes the oil lift from the bowl
into the sight feed dome.
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Injection Lubricator
By a pressure signal, a piston placed in
a small rod pump is activated. This way, small quantities of oil are
injected.
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Micro Mist Lubricator
Oil dosed. instead of entering the air
flow directly, goes through a nozzle towards the oil receiver. This system
makes that the thickest drops are held, assuring an extra- fine spraying.
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Centralized Lubrication System
They make
the air bubble in the oil, after provoking a pressure difference to assure
the bubbling.
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