We all want a safe workplace with efficient operations. The same applies when you are a manager of a workplace that uses pneumatics. Compressed air may be safe, but you still need to implement standard guidelines. Do you know how to practice basic pneumatic system maintenance and preventative care?
At SMC Pneumatics, we believe that you ought to practice regular maintenance to ensure that your systems last for a long time. After all, pneumatic parts are less likely to wear out over time and cost less in the long run. If you practice these steps, even in the case of increased automation, then you will have an efficient workplace.
Prioritize Employee And Operator Safety
Pneumatics in the right hands can create a very safe workplace. For one, pneumatics only requires using natural air, that we breathe. Air is not as combustible as the air used hydraulics, meaning there is a smaller risk of starting a fire or causing an explosion.
Despite this, the compressed air is powerful for a reason. If a cylinder goes flying from the machine, for example, there’s a great chance that it can hit someone and seriously injure them. Make sure to have procedures in place about preventing such accidents, and cut the power when performing standard repairs or checks. Implement shut-off valves so that operations will stop immediately in the case of an emergency, without requiring intense manual labor.
To a lesser extent, the air used for pneumatics must be safe enough for the operators to breathe. This applies even if you use specially filtered gases. If the machine starts leaking, you want your workers conscious so as to make repairs.
Thus, the machines and systems need to be set up in well-ventilated rooms with regulated temperature. That will avoid unwanted mold within the machine and outside of it, and ensuring that there won’t be sudden changes in heat or cold.
Identify Leaks As Soon As Possible
Unexpected pressure drops mean that your machine isn’t operating as efficiently as it should. After all, the airflow provides the force that a pneumatic system uses to generate energy and function. If you have a leak, then you lose that necessary power and the system has to work twice as hard to reach the same output.
Check all of your seals to ensure that no air is escaping; this has the double purpose of preventing oil droplets from entering the system. Measure air pressure with an external gauge, in case your mounted regulators are failing.
Have adhesive on hand to seal leaks, or gaskets to conduct fast repairs. Have steps on hand to apply the adhesive safely and efficiently, so that the air cannot escape the machine. That way you can maintain pressure and not worry about the rest.
Record Shelf Life Of Individual Pneumatic Components
Pneumatic parts, as mentioned, will last longer than their electric, mechanical or hydraulic counterparts. With that said, they will eventually lose their quality over time. It’s more efficient to know when you need to make a replacement rather than having to make an order at the last minute.
Conduct your research about which parts are repairable or not. Some cylinders only require their inner chambers to be fixed once in a while, while others with cinched ends are disposable and must be replaced within a shorter window of time. Different operations will determine if you want a various type of cylinder.
Keep an electronic spreadsheet of the specific parts that you use, ideally on a digital calendar. Then when a part runs the risk of wearing out, you receive a notification on when to order a new model. An intern or office manager can contact the manufacturer to ensure that the component hasn’t been discontinued, or how to find a similar substitute.
Check And Replace Your Filters When Needed
One marvelous aspect of natural air is that it contains more than oxygen and nitrogen. You can also find water vapor, tiny particles, and even oil droplets within the blend of gases. These run the risk of entering your machine. While water vapor can rust and freeze your parts, seriously damaging them, oil and sediments are more likely to cause clogs and stop airflow.
Filters are designed to condense water droplets, catch micron-sized sediments, and stop oil clogs from entering the machine. Some are disposable, while others require replenishment of gels and other parts. After a point, however, they do get clogged and lose their potency. That’s why you need to check them from time to time, to see how much dirty air is entering your system.
Mind that this still applies if you use pure gases in your pneumatic machine. We don’t recommend doing this because of substitutes such as argon and neon having higher price points. Tiny particles can still enter the system, especially if you have a system that also uses hydraulics.
Create Regular Cleaning Schedules
Even if you have disposable parts, you need cleaning as part of your maintenance program. Humans shed seventy percent of dust that enters the air, and entropy ensures that there is a remaining thirty percent. Other bits of dirt and grime can enter, even with automation.
Regular cleaning removes the amount of dust and grime that can potentially enter a workplace. Instead of having to scrub layers, you can gently wipe away the dirt without as much effort. There is less effort in the long-run, and a smaller risk of hazards within the environment. You especially need to clean if doing food processing or medicine, to abide by federal regulations.
Wipe down the exteriors of your actuators and cylinders from time to time. Use microfiber cloths if possible and remove as much liquid as possible. Keep an eye on disposable cylinders’ cinched ends and be sure to clean or replace any piston rods. That will ensure optimal machine function.
Develop A Maintenance Plan With SMC Pneumatics
SMC Pneumatics is ready to help you find the right preventative maintenance for your workplace. Learn from our experts about the filters, gauges, and regulators. We’ll also make recommendations on when you need to replace your parts, and what substitutes to choose when companies cancel their products.
Contact us today to find out about the parts that you can get. SMC Pneumatics can provide the parts and know-how that you need to create a safe industrial environment.