No one likes a broken pneumatic machine. Air-driven operations are supposed to cost less in the long run, and you want to avoid a slowdown in production. Yet troubleshooting your pneumatic system issues is part of the job.
Troubleshooting can save you on costs in the long-run. Suppose, for example, that you are a dentist who uses pneumatic tools in every drill. If you have a hygienist or partner on hand who can identify why a drill is not working, you won’t have to order a new part every time.
For larger-scale operations, problems with the pneumatics can hinder production and affect your profit margin as a result. In the case of food and medicine manufacturing, a machine not working could lead to violations in regulation. Thus, you need to know how to solve machine and system issues.
Steps For Pneumatic Troubleshooting
Fixing your pneumatic machine or system doesn’t need to be complicated. A little bit of common sense can go a long way. Take a look at these basic steps, and incorporate them into your maintenance routine.
Keep The Manual And Schematics On Hand
This step is useful in all industries, including pneumatics. A manual or a layout of the schematics can tell you common problems that may happen, such as particles clogging the machine or the wrong current being used.
Schematics provide a baseline by which the machine should function, such as the standard airflow and motor speeds. They provide a layout of the entire machine, control circuits and all. You can compare your machine performance with that in the schematics.
Usually, a pneumatics store will have a manual for purchase. We have a few for certain systems, so be sure to purchase one if you have misplaced the one that came with your parts. If in the worst-case scenario you can’t find a manual, then reach out to a pneumatics specialist for advice on receiving one.
Check Your Current Connections
It may seem obvious, but when you are doing repairs, make sure that the power is turned off, and that there is no air flowing through the machine. You don’t want to get electrocuted or for the machine to damage any operators. A good way to get injured is for compressed air to move a cylinder in the wrong direction.
Many electric actuators run on a DC current rather than AC, so determine which one you are using. It could be the wrong source of power is affecting the machine’s performance. You could improve operations drastically by making the switch.
On that same note, if you have an electric actuator, a poor connection may explain why the machine isn’t working. Make sure that no water or other liquids have shorted out cables. Check for wear and tear or for twisted cables. Food processing has to consider this issue to ensure that working areas are sterilized.
Test Your Air Pressure Regulators And Control Valves
Once you have the schematics on hand, you can start running your machine carefully to figure out where it’s going off the baseline. It could be a situation as simple as a valve not opening or closing properly. Or it could mean that a part is failing and requires replacement.
Air pressure within the machine flows depending on if a valve operates properly. If they don’t close properly, then the pressure drops, which means you lose power. If the valves fail to open, then it breaks the circuit.
Another potential cause of lowered air pressure is system leaks. One simple example of a leak is a flat tire; there is a reason why gauges measure the air pressure within the rubber. Test for these if the valves are working fine, using an external gauge if possible.
Regulators are designed to ensure that you can control your air pressure at any point in the pneumatic circuit. If a regulator is failing, then that means your air pressure is not consistent, and the machine cannot operate as normal.
Clean Out Your Valves And Pathways
One common problem with pneumatic machines is the risk of foreign particles entering the system. Due to many operators using the regular air around us, many different molecules enter the air compressor along with the necessary natural gases. These particles tend to be on the micron scale and too tiny for the human eye to see. Even though they are small, any sort of droplet could be affecting your operation.
This happens most commonly with water vapor. The water molecules can cause parts within the machine to rust and wear out earlier than they should. In some cases, the molecules can freeze under extreme conditions and cause even more damage, such as with air brakes. You can identify water by the droplets, or if you see a milky substance within the machine.
Oil droplets are also an issue. In addition to being present in the case of an overfilled air compressor, oil can enter in the case of leaks. These can cause clogging and block airflow.
Finally, there are solid particles. Usually, these are dirt and grime on the microscopic level. Such dirt can cause clogs the way that oil can.
One step to preventing these particles from entering the system is to check your filters, replacing disposable ones. Gel filters change color when they have reached their threshold. For reusable filters, check from time to time that they are clean. Wipe down your pathways if you can on seeing water droplets.
Become A Better System Operator With SMC Pneumatics
SMC Pneumatics wants to ensure that you have access to knowledge about how to repair your pneumatic machine. We have a team of experts who are ready to recommend what replacement parts you need, and what models are good when companies discontinue the actuators, valves or motors that you need.
Reach out to us today to learn more about fixing your compressed air system. SMC Pneumatics is ready to help you out in refining your machine, and optimizing production. Let us ensure that you never have a slowdown when working with basic or complicated pneumatics.