Efficiency, reliability, and safety are priorities for any equipment manufacturer or operator. Like any piece of equipment or machinery, preventative maintenance helps reduce wear and tear, improve performance, and keep your pneumatic system operating better and longer. Does your pneumatic system maintenance plan cover the basics? Including the steps below will help you improve operational efficiency and increase uptime.
Check All Components for Air Leaks
Gradual or sudden pressure drops indicate operational issues that are typically caused by system leaks. Since air is the power behind a pneumatic system, leaks require pneumatic systems to work twice as hard to operate. Even then, performance will remain less than optimal until the issue is addressed.
Applying soapy or foaming fluid to potential leak points in your system can help you locate leaks. Depending on the location and size of the air leak, a gasket replacement, application of adhesive, or complete component replacement may be necessary.
Inspect and Lubricate Seals
Seals wear naturally over time, and failure to replace them on a regular schedule can lead to leaks, pressure loss, and system malfunctions. Your pneumatic system maintenance schedule should include checking seals for cracks and wear and lubricating as necessary. If a seal needs replacing, reference the OEM manual to ensure you install the correct size and material for your application.
Remove and Inspect Filters
Air contamination causes numerous system issues. Filters need regular changing, but the frequency depends on the system usage and operating conditions. Carefully check and replace filters that are dirty or damaged. Maintain a log to keep a consistent schedule, adjusting the inspection frequency with increased machine use.
The location of your air compressor is another factor in pneumatic system performance. As a best practice, always install air compressors in a well-ventilated area with minimal exposure to environmental contaminants.
Replace Worn or Damaged Components & Parts
Issues including inconsistent pressure, grinding, clicking, and sluggish operation can all be caused by bad components. A thorough visual inspection will help you identify signs of wear or corrosion, loose fittings, and other types of damage. Replace parts as needed and make sure they are properly lubricated to prevent premature wear and maintain smooth system performance.
Monitor Air Prep System & Control Valve Functionality
Maintaining proper air flow and pressure is critical to efficient pneumatic system performance. Regularly inspect air preparation system components and control valves for leaks, wear, damage, and contamination. Perform a visual inspection while the system is not operational, as well as evaluate the performance of individual components during operation.
Maintain a Consistent Cleaning Schedule
Dirt and grime accumulate over time, even in the cleanest automation facilities. Prevent buildup by regularly wiping surfaces with a lint-free cloth. Cylinders, actuators, and other system components should also be wiped clean and relubricated as part of your regular pneumatic system preventative maintenance plan. A regular cleaning schedule will help ensure optimal machine function and prevent contamination that can quickly damage the air system and components.
Knowing When to Evaluate the System Design
If performance issues persist despite regular preventative maintenance, the system design could be the root of your problems. In many cases, these problems can be resolved by system recalculations and modifications to the parts and components used. A pneumatics expert can help you perform an analysis and provide recommendations to improve system efficiency.
Are you an OEM or equipment operator interested in learning more about pneumatic system maintenance and optimization? From product support to system troubleshooting and redesign, we have you covered. Contact us to discuss your application with a pneumatics technician.