Pneumatic system is a network of parts that uses compressed air to power automated machines. From factory automation, robotic gear to automatic doors, pneumatics are all part of industrial efficiency. These systems utilize and direct compressed air in circuits, converting it into mechanical energy to work on tasks.
But even well-designed pneumatic systems sometimes develop performance issues. When this occurs, diligent troubleshooting is called for. Whether it is a future loss of pressure or a slow-moving actuator, pinpointing the cause can cost you money in downtime.
The following are five tips from an expert on how to effectively and safely troubleshoot your pneumatic system.
1. Prioritize Safety and Ask the Right Questions
First, switch off the source of power and relieve stored air pressure. Compressed air is dangerous, and lack of proper control has caused injury and property damage. Safety equipment should always be used.
Ask yourself:
What's running—or failing to run—under operating conditions?
When did the issue begin—immediately or slowly over time?
Where does the issue occur—is it during startup, in mid-cycle, or upon shutdown?
Abrupt failures point towards mechanical failure or faulty parts. On the other hand, gradual failures are usually due to leaks, contamination, or faulty components.
Check your records of maintenance to look for recurring faults, which will help you determine:
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Where to begin your inspection
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Why it persists
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How to prevent it occurring in the future
2. Check the System and Check Documentation
Before attempting any repair, ensure that you have an idea of how the entire system and its subsystems function. The majority of pneumatic systems come with two key documents:
Schematic Drawing – Functions as a map, showing flow rate, pressure points, cylinder stroke length, etc.
Service/Maintenance Manual – Informs you of potential issues and recommended repair techniques.
Also, carry out a visual inspection prior to work:
- Check for leaking hoses, battered components, or obstructed filters
- Check pressure regulators to ensure smooth airflow
- Look for pinched or ruptured lines
- Replace or clean filters when dirty
If you're unsure about an item, ask questions and discover how it functions with the rest of the system.
3. Operation the System and Isolate Subsystems
Turn on the system upon inspection to observe it functioning. This phase will most likely reveal issues directly and can greatly reduce the time spent troubleshooting.
Once you have located a problem:
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Turn off the system once more
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Release any built-up pressure
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Isolate subsystems to limit your diagnostic domain
Because pneumatics are networked, one failure will affect many areas. Isolating subsystems allows you to test individual components without interference, but at the cost of more safety precautions—especially when testing internal pressures.
4. List and Conduct Diagnostic Tests
Now that it's time to make a list of probable causes based on what you observe. Narrow it down by using particular tests, such as:
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Pressure tests with a gauge
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Flow rate measurement with a flow meter
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Actuator alignment tests
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Valve performance tests
The objective is to correlate symptoms with causes and eliminate improbable sources. It sounds complicated at first but is vital to a successful repair.
5. Repair, Replace, and Report
After determining the problem, make a decision to repair or replace the bad component. Every decision has sacrifices:
Repairing can save part costs but cost more in downtime
Replacing can recover functionality quicker, but at higher initial cost
Take inventory availability, urgency, and in-house resources into consideration when deciding this.
Lastly, make it all official. Write down what the problem was, how it was fixed, and modify your schematics if modifications were done. All this will make the next maintenance and troubleshooting much easier.
Need Reliable Pneumatic Solutions?
If you require high-quality pneumatic systems or accessories, HAK Fluid Power Equipment LTD is here to serve you. We supply high-quality pneumatic products and expert advice tailored to your sector needs.
Contact us today and speak with an expert to keep your systems performing at their best.