Installation, commissioning, and fault analysis of the pneumatic transmission system
The stability of the pneumatic transmission system's operation depends on the correct selection and installation of pneumatic components. Regular inspection and maintenance are necessary to promptly detect and handle the precursors of faults in pneumatic components and systems, ensuring their normal operation and extending their service life.
1. Use and maintenance of pneumatic systems
To ensure the long-term stable operation of the pneumatic system, the corresponding maintenance measures are as follows:
(1) Every day, the water in the filter should be drained, and the oil level height of the oil mist lubricator and its adjustment condition should be checked.
(2) Every week, check if there is any dust or iron filings on the signal generator, examine the pressure gauge on the pressure reducing valve, and check if the oil mist lubricator is working properly.
(3) Check the sealing condition of the pipe connection every three months.
(4) Check every six months whether the support points of the piston rods in the cylinder are worn.
2. Common Faults and Troubleshooting methods of Main Components in Pneumatic systems
Generally, after a newly designed and installed pneumatic system is properly adjusted, it is less likely to malfunction for a period of time. Normal wear and tear will only occur after several years of use. The causes of general system failures are as follows.
(1) Blockage of components.
(2) Internal faults of the control system. Under normal circumstances, the probability of control system failures is far lower than that of sensors in contact with the outside or the machine itself.
Common faults and troubleshooting methods of directional valves are shown in Table 1-2, and common faults and troubleshooting methods of cylinders are shown in Table 1-3.
Table 1-2 Common Faults and Troubleshooting Methods of Directional Valves
| Serial number | Fault | Reason | Exclusion method |
| 1 | not change direction | The sliding resistance of the valve is large Poor lubrication |
Carry out lubrication |
| The sealing ring of the O-ring valve is deformed | Replace the sealing ring | ||
| Dust gets stuck on the sliding part | Remove the dust | ||
| Spring damage | Replace the spring | ||
| The operating force of the valve is small | Check the valve control part | ||
| The piston sealing ring is worn | Replace the sealing ring | ||
| Diaphragm rupture | Replace the diaphragm | ||
| 2 | The valve generates vibration |
Low air pressure (pilot-operated) | Increase the operating pressure It adopts a direct-acting type |
| Low power supply voltage (solenoid valve) | Increase the power supply voltage Use low-voltage coils |
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| 3 | Alternating current electromagnet There is a beeping sound |
The Type I movable core has poor sealing | Check the core contact and sealing performance Replace the core assembly when necessary |
| Dust enters the sliding parts of the I and T-shaped cores. Prevent the movable iron core from coming into close contact |
Remove the dust | ||
| The rivets of the T-shaped movable iron have fallen off. The core layers are separated and cannot be attracted together |
Replace the movable core | ||
| The short-circuit ring is damaged | Replace the fixed iron core | ||
| The power supply voltage is low, and the external wires are pulled too tightly | The lead wire should be spacious | ||
| 4 | The operating time of the electromagnet Large deviation or inability to move |
*The movable core is rusted and cannot be moved: *When using pneumatic components in a high-humidity environment, air leaks into the magnet part due to incomplete sealing. *Low power supply voltage; *Dust enters the sliding part of the moving iron core, deteriorating the movement condition |
*Rust removal of the iron core *Repair the external seal and replace the broken seal. *Increase the power supply voltage or use a coil that matches the voltage: *Remove the dust |
| 5 | The coil is burned out | *High ambient temperature; *Fast recycling; *Because the current is large when attracted, the power consumption per unit time is high, *The degree rises, and the insulation is damaged, causing a short circuit. *Dust trapped between the valve and the core cannot attract the movable core; *There is residual voltage on the coil. |
*Use within the specified temperature range of the product. *Use advanced solenoid valves; *Use pneumatic logic circuits; *Remove dust; *Use the normal power supply voltage and a coil that matches the voltage. |
| 6 | When the power is cut off, The movable core cannot be retracted |
*Dust enters the sliding part of the movable iron core | *Remove the dust |
Table 1-3 Common Faults of Cylinders and Their Troubleshooting Methods
| Serial number | Fault | Reason | Exclusion method |
| 1 | *External leakage *There is air leakage between the piston rod and the sealing bushing. *There is air leakage between the cylinder block and the end cover. *There is air leakage from the adjusting screw of the buffer device. *Internal leakage *There is gas leakage at both ends of the piston. |
*Wear of the bushing seal and insufficient lubricating oil *Piston rod eccentricity *There are scratches on the piston rod *There are impurities in the mating surface between the piston rod and the sealing bushing, and the sealing ring is damaged. *Poor lubrication, the piston rod is stuck. *There are defects on the mating surface of the piston, and impurities have squeezed into the sealing ring |
*Replace the bushing sealing ring and enhance lubrication *Reinstall to ensure that the piston rod is not subjected to eccentric loads *Replace the piston rod *Remove impurities and install dust covers; *Replace the sealing ring *Reinstall; *Replace the parts with severe defects and remove impurities |
| 2 | *The output force is insufficient and the movement is unstable |
*Poor lubrication *The piston or piston rod is stuck. *There is rust or a defect on the inner surface of the cylinder. *Condensate water and impurities have entered |
*Adjust or replace the oil mist lubricator *Check the installation condition and eliminate eccentricity. *The troubleshooting method should be determined based on the size of the defect *Strengthen the management of air filters and water separators, and discharge sewage regularly |
| 3 | *Poor buffering effect | *The sealing performance of the sealing ring The buffer part is poor *Damaged adjusting screw *The cylinder speed is too fast. |
*Replacement rate sealing ring *Replace the screw. *Study whether the structure of the buffer mechanism is appropriate |
Above is Installation, commissioning and fault analysis of the pneumatic transmission system content, To learn more related information, visit https://www.joosungauto.com/.
