12 Step Store

12 Etapes To Fix Pneumatic Systems

Fix a pneumatic system was considered an art, a science, or a just success-or-the luck of missed blow. In the spirits of personnel of discussion, of directors of production, and of directors of plant, the repairs of word done to appear of the pictures of hours of dead time and of lost production.

Nevertheless, when reduces to its basic elements, fixing a pneumatic system is a detailed procedure. Use this process can press the capacity to determine that the problem is, the probable cause of the failure or failure, and a solution.

Every pneumatic circuit has a logical sequence of operation that can imply the logical moment, the feeling pressure, the position that feels, and the speed regulation. The repairs is established when the circuit works not properly.

The certain diagnosis and the general steps of essay can be applied to any problem of repairs, if the problem arrived to the start of a new system or to a failure of a current system.

Think the security first
The security always should be an essential worry of personal discussion. The compressed air is a volatile element in a pneumatic circuit. Air the receiver reservoirs exploded, causing the harsh injury to the personnel and the damages to the property. It is imperative to relieve pressure in a receiver reservoir before to do any repairs.

The air is also extremely reducible, that is another reason to be prudent in the approach to fix a pneumatic system. While working with above the loads that are supported by the cylinders, but not automatically closed to key in place, block the load before maintaining the system to prevent to fall or divert.

A lot of pneumatic systems are checked by the electric or devices electronic. Before attempting the service or the repair on these components, to be sure that the electric nutrition was extinct.

The pneumatic directional check valves that use electric solednoa¯des to work the valve spool often is equipped with the orders manuelles (the fig. 1) that can be used during the repairs to work the system.

The pneumatic valves of lock-out (the fig. 2) are excellent devices of security that, when used properly on the pneumatic systems, can prevent the accidental operation. To guarantee a sure condition always should be the first step in the repairs systems pneumatic.

Ask the three W
When a failure in the system arrives, the trade pressures to weave big dead time in the spirits of all interested. Before beginning the repair of a system, to stop and to ask these three questions:

Which is or does not arrive in the operation of the system?

When did the problem begin? Etait-cet a sudden failure or a gradual failure?

Where is in the machine cycle the problem arriving? Did etait-cet to the start or after the system work a little?

Which is or does not arrive in the system often can be replied by the system operator. The responses to the questions as the speed of mechanism of slow positionnement or the inability of the mechanism of positionnement to move could take themselves to looks for a low debit or a low pressure.

Ask, "When the problem began? 'Can take often to the repairs of the steps that look for components or escapes reaches. The sudden failures can indicate to the cuts and to the possible mechanical problems, the ruptures in the lines, or the other irretrievable failures. While determining the when, the problem research can be reduced in his range.

Where in the cycle of required machine, "is the problem arriving it"? can reveal a reproducing condition.

If the good reports of discussion were kept, reproducing problems should have been recorded. These information do the repairs process a lot of easier.

A discussion person that stops and asks the three W can reduce the dead time in not in front of to guess to which is bad. Nevertheless, if these questions do not produce a satisfactory diagnosis the person of discussion must begin the repairs mechanics while inspecting visually the machine.

Do a visual check
Lead the machine will discover often problems as pipes carried or of explosion, the detached components, and the components broken. This is the time to become familiar with the contained components in the pneumatic system.

Itself unknown with the components, or itself unknown with the machine operation, ask as much pertinent questions of the system as possible. Before trying to work the repairs of system or attempt, to understand the correlations of all the components and the under system found on the machine.

Read the outlines
Every pneumatic system should have two forms of documentation that will help the repairs. A document is a drawing schedmatique of the pneumatic circuit (the fig. 3). The outline is a road card. It explains not only the operating function of the components but is also a valid diagnostic tool.

The outline contains useful the news of the locations of no test of pressure; the parameters of pressure of regulating ones and of other valves of pressure; the debits in the system; the lengths of blow of cylinder, and air speeds motors just like an equipment bill for the system. This information type can help in to determine if the system works in its conception parameters.

With the outlines furnish by the manufacturer, another series of documents, the manual of service/discussion and its updated bulletin of service, can be available to help the diagnosis and the repair of the machine. These can contain the news of the problem that arrived.

Work the machine
After having familiar become with the components and the operation of the pneumatic system, to begin the machine and works it to obtain a view of first hand of the failure. See if the failure that was retrieved arrives again. While working the machine, execute a visual check.

Some questions to ask during the inspection:

Is there excessive escape of air?

Are the system pressures at the specified levels on the outline or in the discussion manual?

If there are checks manuals for the machine, they feel stiff or detached in their operation?

Are the components this movement, moving itself easily or irregularly?

While working the machine, any abnormalities can become evident, shortening the time repairs.

Countercheck all the services
Before attempting the repair on the machine after it was worked, again checks it to see if supplies furnished by machine was extinct. The check to see if the stored pressure remains in the system, because this stored pressure can cause the placement in premature action of the mechanisms of positionnement of the system and causes the injury to the personnel and the damages by machine.

Isolate of the under systems
A failure in a part of machines it can be caused by a failure in an under different system on the machine. Isolate the under systems, can help the home on a system at once. Reduce the sector diagnostic by the isolation of under systems demands the additional precaution while working the machine.

Any lines that were disconnected and any harbors that were opened should be properly blocked to prevent from the escape of useless air and the entry of contaminate.

While working the machine, a watch close should be kept on the pressures in the system, therefore the admissible pressures maxima are not surpassed. The prudence and the security are the two keys to this diagnostic step.

Do a list
During the preceding step, the immediate problem can be completely evident. Nevertheless, in the repairs, the evident one cannot be the initial cause.

As an example, the evident problem can be the speed of mechanism of slow positionnement but the initial cause of the problem could be the insufficient lubrication, no lubrication because of a defective lubricant (the fig. 4), or the bad seals in the valve of directional check that checks the mechanism of positionnement.

After doing a list of possible causes, verifying these items on the list and the eliminates without returning on the ground covered previously. This list will reduce also the demanded time for the repairs and can eliminate the parties that exchange the syndrome that accompanies often the repairs.

The example of speed of mechanism of slow positionnement shows why a meticulous comprehension of component and of principles of operation of system precisely is demanded to equal the problem to the cause.

After doing a list and a reduction of the possible causes, this is now the time to take a decision on which one of the remaining causes are the most probable to be the reason for the failure. Attain this conclusion can, first, appear difficult but this step is essentially the point of departure for the portion of repair of repairs. Until now the system was evaluated, now this is the time to try the conclusion.

In the example, trying the conclusion can be simply the need to add lubricant to the lubricant or does an adjustment to the rate of drop of the lubricant.

Direct the various tests as the pressure checks with a gauge specifies, verifying the line of mechanism of positionnement, verifying the debit in the system with a meter of flow, or the temperature that verifies system of air, can more reduce the number of causes that remain on the list and precise precisely the cause.

Repair or replace
Try the conclusion automatically takes to decide if to repair or to replace a component. A lot of factors can influence this step. Repair the parties right away for the reinstallation on the dead time of increases of machine, and the factor of cost of this dead time is a significant consideration.

Simply to replace the party with a new one or rebuilds component would reduce the quantity of dead time; nevertheless, the question of cost of inventory becomes now a factor.

Another not at all that can influence the repair-or-replaces the question is component availability. Evidemment if the component is not easily available, then to repair can be the only alternate one. Always another aspect can be the internal capacity to do the repairs.

After the failure was corrected, a final step remains, the need to retrieve the conclusions.

Retrieve that you did
The administrative work often is neglected, but in the case of pneumatic repairs this is a vital party of the procedure. This administrative work helps to maintain a changes of file of, the problems, and the solutions that arrived to the individual machines. Updated them schedmatiques are necessary to keep this tool diagnostic and current precise. Retrieve do serves also of a good reference has any problems reproduce themselves in the future.