What is a Pneumatic Ball Valve?

A pneumatic actuated ball valve uses compressed air to automate the control of media. Pneumatic actuated ball valves don’t rely on a motor, but they do require electricity when paired with an integral pilot or solenoid valve.

What is a ball valve pneumatic actuator?

Pneumatic actuator ball valves by the conversion of compressed air energy to mechanical motion. A rotary mechanical motion is required in a ball valve for a 90 degrees turn. Pneumatic actuator ball valves can be single-acting or double-acting.

Single-Acting Pneumatic Actuator

A single-acting pneumatic actuator uses a single compressed air input to turn the valve and a spring to return the valve to the normal position.

Double-Acting Pneumatic Actuator

A double-acting pneumatic actuator has two compressed air inputs to turn the valve and return the valve to the original position.

Ball Valve Pneumatic Actuator Types

There are two main types of pneumatic actuators: scotch yoke and rack-n-pinion. While they both perform basically the same rotational operation on quarter turn ball valves, they do so using a different mechanical technique. Both types are available in spring return and double (direct) acting. Spring return pneumatic actuators will return to a “fail-safe position” upon loss of power or supply air. That position could be open or closed, whichever provides the best result for that system. Double acting pneumatic ball valves will simply remain in their current position when power or supply air is lost.

Rack and Pinion Pneumatic Actuator

Rack and pinion designs include a piston, rack and pinion. As air pressure increases on one side of the piston, it moves the rack inwards and through a gear connection with the pinion it spins the output rotary shaft. Rack and pinion actuators are found across the chemical, pharmaceutical, water processing and oil and gas industries.

Scotch Yoke Pneumatic Actuator

Scotch yoke designs feature a linear-moving piston connected to the rotary shaft by a pin and slot mechanism. As the air pressure increases and moves the piston linearly, it spins the rotary shaft through a cam system (pin and slot), Technology.org explains. “This will then in effect turn the valve and either open or close it.” Scotch yoke actuators are typically found in chemical and general process applications.

How does a pneumatic actuator work on a ball valve?

The most common mechanism for a pneumatic actuator for ball valves is the rack and pinion mechanism. This comprises of the rack (a linear gear) and the pinion (a circular gear). The rack is attached to a piston which is pushed by compressed air to achieve linear motion. This linear motion is converted to circular motion by the pinion. The pinion drives the stem of a ball valve to open and close positions.

To control the pneumatic actuator for ball valves, the compressed air is regulated by solenoid valves. Electrical signals from the controller energize the solenoid valve to either open or close positions allowing compressed air to flow through to both piston sides of the pneumatic actuator. The piston pushes the rack which turns the pinion connected to the stem of the ball valve.

Accessories that you can use with this Ball Valve:

• On/off Indicator
• Namur Standard Solenoid Valve in all Standard
• Pneumatic & Electro-Pneumatic Valve Positioner
• Declutchable Manual Override
• Limit Switches for On/Off Indication at Panel Board
• Filter + Regulator Combination with Pressure Gauge
• Air Lock Valve

How to choose ball valve pneumatic actuator?

Ball valve pneumatic actuator drive with all kinds of computer networking, alone or centralized control, Ball valve pneumatic actuator can use the analog or digital variables two kinds of signal control, supporting various kinds of modern control equipment, wild valve production, Ball valve pneumatic actuator is widely used in domestic petroleum, chemical, electric power, metallurgy, textile, food, medicine, environmental protection, urban construction and the research field,and exported to Europe, America, Middle East and southeast Asia market, well received by users.

Ball valve pneumatic actuator  beautiful and exquisite shape, light weight, waterproof sealing structure. F4 guide rings are installed on moving parts of piston, rack and output shaft to achieve low friction, long life and avoid contact between metals. The installation connection size conforms to ISO5211, DIN3337 and VD1 / VDE3845 as well as NUMAR standards to ensure the interchangeability between ZE actuators and facilitate the installation of solenoid valves, limit switches and other accessories.

Model selection of ball valve double-acting pneumatic actuator:

Ball valve Double acting actuator is used to determine the torque of the valve first. Under normal service conditions, the recommended safety factor is 15 ~ 20%. The safety value is then added according to the fluid medium used by the valve. Increase the safety value of clean and lubricating media by 20%; Water vapor or non-lubricated liquid medium increases the safety value by 25%; Increase the safe value of 40% to the non-lubricated slurry liquid medium; Non-lubricated dry gas medium increases the safety value by 60%; Non – lubricated particulate medium increases the safety value by 80%. The safety value of non-lubricated particle powder medium transported by gas is increased by 100%; According to the torque value calculated above and the torque table of the double-acting actuator using air source pressure, the accurate ZE model can be obtained.

Model selection of ball valve single-acting pneumatic actuator:

Using the single-acting actuator, according to the torque value calculated above and the use of air source pressure, find the single-acting torque table, first check the spring reset end point, then check the end point of air source working pressure, the air source pressure torque should be greater than the spring reset torque, you can get the exact model. Note: In the ZE single gas-controlled output torque table, the “end” torque of the spring reset is the torque of closing the valve, and the “start” torque of the spring reset is the torque of opening the ball valve. The torque at the beginning of the corresponding air source pressure is the torque in closing the ball valve, and the torque at the end of the air source pressure is the torque in opening the ball valve.

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What is a Diphragm Actuator ?

By themselves, valves cannot control a process. Manual valves require an operator to position them to control a process variable. Valves that must be operated remotely and automatically require special devices to move them. These devices are called actuators.

Actuators may be pneumatic, hydraulic, or electric solenoids or motors.

Diaphragm actuators are pneumatically operated and they use an air supply from the control system or other sources. Diaphragm actuators are normally used for control valves, which are a type of globe valve that is typically used to regulate the fluid in order to adjust some process variables, such as pressure, temperature, or flow rate. Diaphragm actuators are used in all sectors of the oil and gas industry except for subsea. The most common styles for diaphragm actuators are known as “direct-acting” and “reverse-acting.”

Pneumatic Diaphragm Actuators

A simplified diagram of a pneumatic actuator. It operates by a combination of force created by air and spring force. The actuator positions a control valve by transmitting its motion through the stem.

A rubber diaphragm separates the actuator housing into two air chambers. The upper chamber receives supply air through an opening in the top of the housing.

The bottom chamber contains a spring that forces the diaphragm against mechanical stops in the upper chamber. Finally, a local indicator is connected to the stem to indicate the position of the valve.

The position of the valve is controlled by varying supply air pressure in the upper chamber. This results in a varying force on the top of the diaphragm. Initially, with no supply of air, the spring forces the diaphragm upward against the mechanical stops and holds the valve fully open.

As supply air pressure is increased from zero, its force on top of the diaphragm begins to overcome the opposing force of the spring. This causes the diaphragm to move downward and the control valve to close. With an increasing supply of air pressure, the diaphragm will continue to move downward and compress the spring until the control valve is fully closed.

Conversely, if supply air pressure is decreased, the spring will begin to force the diaphragm upward and open the control valve. Additionally, if supply pressure is held constant at some value between zero and maximum, the valve will position at an intermediate position. Therefore, the valve can be positioned anywhere between fully open and fully closed in response to changes in supply air pressure.

A Positioner is a device that regulates the supply of air pressure to a pneumatic actuator. It does this by comparing the actuator’s demanded position with the control valve’s actual position.

The demanded position is transmitted by a pneumatic or electrical control signal from a controller to the positioner. The pneumatic actuator in Figure 1 is shown in Figure 2 with a controller and positioner added.

The controller generates an output signal that represents the demanded position. This signal is sent to the positioner. Externally, the positioner consists of an input connection for the control signal (4-20mA), an instrument supply air input connection, a supply air output connection, a supply air vent connection, and a feedback linkage.

Internally, it contains an intricate network of electrical transducers, air lines, valves, linkages, and necessary adjustments. Other positioners may also provide controls for local valve positioning and gauges to indicate supply air pressure and control air pressure (for pneumatic controllers – old controlling methods).

The controller responds to a deviation of a controlled variable from the setpoint and varies the control output signal accordingly to correct the deviation. The control output signal is sent to the Positioner, which responds by increasing or decreasing the supply of air to the actuator.

The positioning of the actuator and control valve is fed back to the positioner through the feedback linkage. When the valve has reached the position demanded by the controller, the positioner stops the change in supply air pressure and holds the valve at the new position. This, in turn, corrects the controlled variable’s deviation from the setpoint.

For example, as the control signal increases, a valve inside the positioner admits more supply air to the actuator. As a result, the control valve moves downward. The linkage transmits the valve position information back to the positioner.

This forms a small internal feedback loop for the actuator. When the valve reaches the position that correlates to the control signal, the linkage stops supplying airflow to the actuator.

This causes the actuator to stop. On the other hand, if the control signal decreases, another valve inside the positioner opens and allows the supply air pressure to decrease by venting the supply air. This causes the valve to move upward and open. When the valve has opened to the proper position, the positioner stops venting air from the actuator and stops the movement of the control valve.

Advantages of Pneumatic Diaphragm Actuators

The benefits of pneumatic actuators come from their simplicity.

Pneumatic actuators’ typical applications involve areas where the conditions involve extreme temperatures, a typical temperature range is -40°F to 250°F.

In terms of safety and inspection, using air and pneumatic actuators avoids using hazardous materials. They also meet explosion protection and machine safety requirements because they create no magnetic interference due to the lack of motors.

Pneumatic actuators are also lightweight, require minimal maintenance, and have durable components that make pneumatics a cost-effective method of power.

Disadvantages of Pneumatic Diaphragm Actuators

Pressure losses and compressibility of air make pneumatics less efficient than other methods. Compressor and air delivery limitations mean that operations at lower pressures will have lower forces and slower speeds.

To be truly efficient, pneumatic actuators must be sized for a specific job. Hence, they cannot be used for other applications.

Even though the air is readily available, it can be contaminated by oil or lubrication, leading to downtime and maintenance. Companies still have to pay for compressed air, making it consumable, along with the compressor and line maintenance costs.

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TOP 5 Pneumatic Rotary Actuator Manufacturers

Festo is a company founded in 1925 and headquartered in Germany that provides actuation technology for the global industry. It has 61 companies and 250 branches worldwide, with approximately 21,000 employees. No matter where you are, Festo has a way to contact you and provide solutions based on your needs.
Festo offers a variety of pneumatic actuators to meet your drive needs.

NORGREN was founded in 1925. Entrepreneur Carl Norgren designed a system dedicated to solving the maintenance and lubrication problems of customers using pneumatic tools and equipment. In 1972, IMI plc acquired NORGREN and became the fluid power division of IMI, providing high-quality pneumatic and fluid control products to customers around the world.

NORBRO is a sub-brand of Flowserve, headquartered in the United Kingdom. NORBRO is committed to providing customers with automated pneumatic rotary actuators. Founded in 1790, Flowserve operates in more than 50 countries and more than 300 locations around the world and has more than 17,500 employees.
Flowserve has many sub-brands, providing a variety of automation solutions for global industrial customers.

CAMOZZI was established in 1964 as a global leader in the design and production of motion and fluid control accessories for industrial automation. With 14 production bases, 50 distributors, 30 subsidiaries and service centers around the world, it can provide fast and convenient solutions to customers all over the world.

Numatics is a sub-brand of Emerson, providing high-quality pneumatic rotary actuators to meet your various needs. Emerson is committed to solving process control challenges for customers. Established in 1890, Emerson is a manufacturer of electric motors and fans. After more than 100 years of development, Emerson has become a leader in global automation solutions.
Emerson also has many sub-brands to provide you with one-stop fluid control solutions.

What is Pneumatic Rotary Actuator?

A rotary actuator is a pneumatic cylinder used to provide a turning or angular movement, allowing a stroke in an oscillating motion through a defined angle. They are durable and give a relatively high force (torque) for size. Rotary actuators simplify a design and can reduce maintenance issues.

Types of Pneumatic Rotary Actuator

Rack-and-pinion

A rack-and-pinion consists of a circular gear (the pinion) engaged to a linear gear (the rack). When actuated, the piston which is attached to the rack moves linearly. Due to the gear connection to the pinion, it rotates it with the attached output shaft effectively turning the linear motion into rotational.

Often two pistons and racks are installed on the opposite side of each other to double the amount of torque on the pinion as shown in Figure 3. In this double acting actuator, the two chambers on the sides are filled with pressurized air which push the pistons to the center. To return the pistons to the initial position, the chamber in the center is in turn pressurized.

The rack and pinion design has a fairly high mechanical efficiency. They can product a torque range from a couple Nm to multiple thousands of Nm.

Scotch Yoke

In a Scotch Yoke mechanism, the shaft of the piston is engaged with a rotary shaft via a pin and a slot, as shown in Figure 5. The linear motion of the shaft causes the pin to rotate. Scotch yoke actuators can be spring return or double acting. These actuators can also be equipped with two opposing pistons to double the amount of torque on the output shaft as shown in Figure 5 on the right. Scotch yoke actuators are heavy duty actuators producing torques ranging from multiple thousands to hundreds of thousands of Nm.

How does Pneumatic Rotary Actuator work?

A pneumatic rotary actuator uses compressed air to generate its operating energy. Some are designed specifically to remotely control valves. The clean, dry air can be provided via a central compressed air station, or in case of a compressed gas system, from the process gas. The waste gas can then be released into the air or a downstream lower-pressure process piping. They are commonly used to automate and remotely control quarter turn or multi-turn valves, like ball or butterfly valves.

A pneumatic rotary actuator consists of one or more air chambers with a piston or a bellows diaphragm. Depending on the design, the air pressure forces the piston or the diaphragm to move creating linear or rotary motion. If the created motion is linear, it then internally converts the linear motion to rotational motion. Pneumatic rotary actuators are durable, offer high force relative to their size and can be used in hazardous environments.

Generally, to drive a rotary valve, a rotary actuator is used. However, there are also designs that use pneumatic cylinders, which create linear motion, to generate torque by means of pivot arms or bearings. However, specifying pneumatic rotary actuators for these applications can simplify the design and increase service life. Pneumatic rotary actuators are self-contained, therefore, their parts are not exposed to contaminants and aggressive environments meaning they are less likely to require maintenance over their lifetime.

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Pneumatic control valve accessories help ensure optimal performance and are an essential component in a pressure control system. Electric switches help bridge the communication gap between a valve operator and control system, helping to control accuracy. Various styles of operators allow for manual and pneumatic actuation of control valves and mounting brackets are used to mount directional control valves to machinery.

Purpose of Pneumatic Valve Accessories

There are five basic reasons that accessories are added to a control valve:

• Improve process control
• Improve safety for the process or personnel
• Improve valve performance or speed of response
• Monitor or verify the valve responsiveness
• Diagnose potential valve issues

Pneumatic Accessories For Pneumatic Actuator

Electro-pneumatic valve positioner:

The valve positioner is the main accessory of the pneumatic actuator. It is used in conjunction with the pneumatic actuator to improve the position accuracy of the valve, overcome the influence of the friction force of the valve stem and the unbalanced force of the medium, so as to ensure that the valve is realized in accordance with the signal from the regulator position it correctly.

Under the following circumstances, a positioner is required:

1. When the medium pressure is high and the pressure difference is large;
2. When the caliber of the regulating valve is large (DN>100);
3. High temperature or low-temperature control valve;
4. When it is necessary to increase the operating speed of the regulating valve;
5. When using standard signals to operate non-standard spring actuators (the spring range is outside of 20～100KPa);
6. When used for split-range control;
7. When the valve realizes the reverse action (the air-to-close type and the air-to-open type are interchanged);
8. When the flow characteristics of the valve need to be changed (the positioner cam can be changed);
9. When there is no spring actuator or piston actuator, it is necessary to achieve proportional action;
10. When using electrical signals to operate pneumatic actuators, power must be distributed to the pneumatic valve positioner.

Solenoid valve:

When the system needs to achieve program control or two-position control, it needs to be equipped with a solenoid valve. When the solenoid valve is selected, in addition to considering the AC and DC power supply, voltage, and frequency, the relationship between the solenoid valve and the regulating valve must be paid attention to. It can be used as “Normally open” or “normally closed”. If you need to increase the capacity of the solenoid valve to shorten the action time, you can use two solenoid valves in parallel or use the solenoid valve as a pilot valve in combination with a large-capacity pneumatic relay.

Air filter pressure reducing valve:

The air filter pressure reducing valve is an accessory in the industrial automation instrument. Its main function is to filter and purify the compressed air from the air compressor and stabilize the pressure at the required value. It can be used for various pneumatic instruments, solenoid valves, Air supply, and voltage stabilizing devices for cylinders, spraying equipment, and small pneumatic tools.

Travel switch (responder):

The travel switch reflects the two extreme positions of the valve switch and sends out an indication signal at the same time. Based on this signal, the control room can betray the switch state of the valve in order to take corresponding measures.

ZECO Valve is a professional pneumatic ball valve manufacturer, if any inquiries, please be free to contact us,

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Pneumatic actuators can be further categorized as scotch yoke design, vane design, and the subject of this post-rack and pinion actuators.

What is a Rack and Pinion actuator?

Rack and pinion actuators are mechanical devices used to automatically open and close valves or dampers, usually for industrial applications.

Rack-and-pinion pneumatic actuators, also called limited rotation cylinders, are rotary actuators used for turning, opening, closing, mixing, oscillating, positioning, steering and many more mechanical functions involving restricted rotation. These actuators are also often used for automation of quarter-turn valves, like ball or butterfly valves.

Pneumatic rack-and-pinion actuators convert the energy of compressed air by means of a pneumatic cylinder to an oscillating rotary motion. The clean, dry, and processed gas required by this actuator is provided via a central compressed air station, which usually supports a range of pneumatic devices in a process system.

Pneumatic actuators, in comparison to their electric counter parts, are generally more durable, better suited for hazardous environments and less expensive. In addition, they often require less maintenance and provide higher torque in comparison to their size.

Rack and pinion actuators convert linear movement of a driving mechanism to provide a rotational movement designed to open and close quarter-turn valves such as ball, butterfly, or plug valves and also for operating industrial or commercial dampers.

The rotational movement of a rack and pinion actuator is accomplished via linear motion and two gears. A circular gear, known as a “pinion” engages the teeth of one or two linear gears, referred to as the “rack”.

Pneumatic actuators use pistons that are attached to the rack. As air or spring power is applied the to pistons, the rack changes position. This linear movement is transferred to the rotary pinion gear (in both directions) providing bi-directional rotation to open and close the connected valve.

Rack and pinion actuators pistons can be pressurized with air, gas, or oil to provide the linear the movement that drives the pinion gear. To rotate the pinion gear in the opposite direction, the air, gas, or oil must be redirected to the other side of the pistons, or use coil springs as the energy source for rotation. Rack and pinion actuators using springs are referred to as “spring-return actuators”. Actuators that rely on opposite side pressurization of the rack are referred to as “direct acting”.

Construction of Rack & Pinion actuator

Most actuators are designed for 100-degree travel with clockwise and counterclockwise travel adjustment for open and closed positions. World standard ISO mounting pad are commonly available to provide ease and flexibility in direct valve installation.

Mounting dimensions on actuator pneumatic port connections and on actuator accessory holes and drive shaft are also common design features to make adding pilot valves and accessories more convenient.

Pneumatic pneumatic rack and pinion actuators are compact and effective. They are reliable, durable and provide good service life. There are many brands of rack and pinion actuators on the market, all with subtle differences in piston seals, shaft seals, spring design and body designs. Some variants are specially designed for very specific operational environments or circumstances.

Indicator

Position indicator is standard for mounting accessories.

Pinion

Pinion is electroless nickel-plated alloy steel for NAMUR mounting of accessories, ISO 5211 and DIN3337 for mounting to valves.

Actuator Body

Extruded hard anodized aluminum allows ASTM6005 body, powder polyester painted. TVC standard is light gray powder polyester paint.

End Caps

Die cast aluminum powder polyester painted in black. Different colors upon request. Also available in PTFE or ENP.

Pistons

The twin rack pistons are made from die cast aluminum then hard anodized. Also available from cast steel and galvanized. The pistons are symmetrically positioned for long cycle life and fast operation. Reversing rotation is simply performed by inverting the pistons.

Travel Adjustment

The two independent external travel stop adjustment bolts can adjust ±5° at both open and close directions easily and precisely.

High-Performance Springs

Preloaded coated springs are made from high-quality material resistant to corrosion and longer service life, which can be changed safely and conveniently to satisfy different requirements of torque by changing the quantity of springs.

Bearings & Guides

Made from low friction, long-life engineered plastics, to avoid direct contact between metals. Maintenance and replacement are easy and convenient.

O-Rings

NBR rubber O-rings provide trouble-free operation at standard temperature ranges. For high- and low-temperature applications FKM or Silicone

How does Rack and Pinion actuator Work?

Double Acting Actuators

Air to Port A forces the pistons outwards, causing the pinion to turn counterclockwise while the air is being exhausted from Port B.

Air to Port B forces the pistons inwards, causing the pinion to turn clockwise while the air is being exhausted from Port A.

Air to Port A forces the pistons outwards, causing the pinion to turn clockwise while the air is being exhausted from Port B.

Air to Port B forces the pistons inwards, causing the pinion to turn counterclockwise while the air is being exhausted from Port A.

Spring Return Actuators

Air to port A forces the pistons outwards, causing the springs to compress, The pinion turns counterclockwise while air is being exhausted from port B.

Loss of air pressure on port A causes the stored energy in the springs to force the pistons inwards. The pinion turns clockwise while air is being exhausted from port A.

Air to Port A forces the pistons outwards, causing the pinion to turn clockwise while the air is being exhausted from Port B.

Loss of air pressure on port A causes the stored energy in the springs to force the pistons inwards. The pinion turns counterclockwise while air is being exhausted from port A.

Common Rack and Pinion Applications

Rack and Pinion actuators are for automation and operation of quarter-turn valves like Butterfly, Ball and Plug valves as used in process industries like chemical, pharmaceutical, water processing, oil & gas, etc.

The actuators are available in two constructions: Spring Return and Double Acting. Mechanical Spring Return is for fail-safe applications and can be assembled for “Fail-Close” or “Fail-Open” safety function.

Double Acting actuators can be used for a “Fail-In-Last-Position” safety function.

Advanced Rack and Pinion Applications

Rack and Pinion actuators are available for a wide range of advanced applications. Most well know are the temperature related trim kits that allow High Temperature or Low Temperature operation.

Other applications are related to manipulating the stroke differently (Full Stroke Adjustment), special coating requirements, special operating media, or fast operating speeds.

For many of these advanced applications, dedicated control accessories are available.

Share your process valve control and automation challenges with application experts, and combine your process experience and knowledge with their product application expertise to develop effective solutions.

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