Lesson 1Flow and Speed Control Parts: Flow Control Valves, Needle Valves, One-Way Flow Controls, Quick Exhaust ValvesYou will learn how flow and speed control devices shape actuator movement. The section compares needle valves, one-way flow controls, and quick exhaust valves, with guidance on meter-in versus meter-out setups for smooth operation.
Needle valves versus flow control valvesMeter-in versus meter-out configurationsOne-way flow controls for cylinder speedQuick exhaust valves for fast retractionAvoiding instability and stick-slip motionLesson 2Air Preparation Units: Filter, Regulator, Lubricator (FRL) Functions and Selection GuidelinesThis section explains FRL unit roles in protecting pneumatic systems. You will learn how filters, regulators, and lubricators work, how to size them, and how to select layouts that match air quality and flow demands in your setup.
Filter grades and water removal methodsRegulator types, ranges, and droop behaviourLubricator principles and when to avoid oilSizing FRLs for flow and pressure stabilityFRL placement, bypass, and maintenance plansLesson 3Basic Properties of Compressed Air: Pressure, Flow, Temperature, Compressibility, Units (psi, bar, l/min)This section reviews key properties of compressed air and their units. You will connect pressure, flow, temperature, and compressibility to real behaviours in circuits, including pressure drop and energy use in practical applications.
Gauge versus absolute pressure conceptsFlow units: l/min, SCFM, and NL/minTemperature effects on density and moistureCompressibility and pressure drop basicsEnergy use and leakage impact on costsLesson 4Sensors and Feedback Devices: Pneumatic and Electronic Proximity Sensors, Mechanical Limit Switches, Cushioning SwitchesThis section presents common pneumatic sensing and feedback options. You will compare mechanical, pneumatic, and electronic devices, and learn how to mount, protect, and wire them for reliable position signals in your machines.
Mechanical limit switches and camsPneumatic signal sensors and logic useMagnetic proximity and reed sensorsElectronic proximity and analog feedbackMounting, wiring, and protection practicesLesson 5Pneumatic Actuator Types: Single-Acting vs Double-Acting Cylinders, Rodless Cylinders, Guided Cylinders, Cushioning and Mounting StylesYou will explore major pneumatic actuator types and their uses. The section compares single-acting, double-acting, rodless, and guided cylinders, including cushioning, mounting, and selection trade-offs for different tasks.
Single-acting versus double-acting cylindersRodless cylinders for long strokesGuided cylinders for side load controlAdjustable cushioning and end stopsMounting styles and alignment issuesLesson 6Valve Types and Functions: 2/2, 3/2, 4/2, 5/2 Directional Control Valves, Pilot-Operated vs Direct-Acting, Spring Return vs DetentedThis section explains common directional valve symbols and functions. You will compare 2/2, 3/2, 4/2, and 5/2 valves, direct-acting versus pilot-operated designs, and spring return versus detented actuation for control.
Reading valve porting and position symbols2/2 and 3/2 valves for on-off and actuation4/2 and 5/2 valves for cylinder controlDirect-acting versus pilot-operated valvesSpring return, detented, and manual overridesLesson 7Force and Stroke Calculations: Converting Pressure to Force, Effective Piston Area, Accounting for Push/Pull Force Differences and FrictionYou will learn how to convert pressure into usable force and stroke work. The section covers piston area, push versus pull force, friction allowances, and safety factors used when sizing cylinders for applications.
Calculating piston and annulus areasConverting pressure to theoretical forceAccounting for friction and efficiency lossPush versus pull force and rod bucklingStroke length, work, and safety factorsLesson 8Pressure Safety Components: Pressure Relief Valves, Safety Valves, and Pressure SwitchesHere you study devices that protect people and equipment from overpressure. The section compares relief valves, safety valves, and pressure switches, covering setpoint choice, installation, testing, and applicable standards.
Functions of relief and safety valvesPressure switch types and contact logicSelecting setpoints and blowdown marginsInstallation rules for discharge pipingInspection, testing, and documentationLesson 9Materials and Fittings: Tubing Materials, Fittings, Lubricants, Seals Compatibility and Contamination ConsiderationsThis section covers tubing, fittings, seals, and lubricants used in pneumatics. You will compare materials, pressure ratings, and chemical compatibility, and learn how contamination and poor selection reduce system life.
Tubing materials, ratings, and bend limitsPush-in, compression, and threaded fittingsSeal materials and media compatibilityLubricant types and interaction with sealsContamination sources and cleanliness controlLesson 10Common Cylinder Sizes and Typical Force Ranges for Small Press-Fit Applications (approx. values for 1/4"–1" bore)Here you relate bore size to achievable force for small press-fit tasks. The section provides approximate force tables for 1/4"–1" bores, discusses stroke limits, and highlights safety margins and fixture stiffness.
Typical bores from 1/4 inch to 1 inchForce estimates at common supply pressuresEffect of stroke and speed on press qualityGuiding, fixturing, and side load limitsSafety margins for repeatable press forces
