Key points of this article
- The state of the pneumatic circuit is an important factor affecting the stable operation of pneumatic equipment. The effects of air leakage and loose joints will gradually accumulate.
- Must be checked beforeUnload the workpiece, stop the machine, turn off the air supply and release the residual pressure, it is strictly prohibited to disassemble it under load or under pressure.
- Common effects: drop in air pressure, slow movement,Unstable clamping, loose parts, unstable vacuum gripping, abnormal load balance, increased energy consumption。
- It is not recommended to disassemble key components such as safety valves, air control modules, and load balancing systems on site. You should contact the manufacturer or professionals.
In the daily use of Pneumatic Industrial Manipulator, pneumatic balancing cranes, vacuum suction cranes and supporting custom tooling, the state of the air path is one of the important factors affecting the stable operation of the equipment. This article explains the common effects of pneumatic circuit failures, on-site inspection steps and daily prevention suggestions from the perspective of manufacturer maintenance data, for reference by operators, equipment supervisors and maintenance personnel.
Safety reminder:Before inspecting air hoses, joints, valve groups, vacuum suction cups or custom tooling, you must first confirm that the site is in a safe state - unload the workpiece, stop the machine, turn off the compressed-air supply, and confirm that the workpiece has been stabilized and surrounding personnel have left the dangerous area.It is strictly prohibited to disassemble the air hose, quick-in connector, valve body or fixture air line when the load is suspended, the workpiece is clamped by the fixture, or there is still residual pressure in the equipment.If it involves pneumatic control modules, safety valves, load balancing systems, load-bearing fixtures, core components of vacuum generators, etc., you should contact the manufacturer or professionals for handling.
01Common effects of air line leaks and loose joints
- The compressed-air supply pressure drops and the equipment operates unstable: When the pressure is insufficient, it may be difficult to start, weak in movement, or slowed down.
- Slow movement affects production rhythm: The response of the actuator becomes slow, and the lifting and lowering are inconsistent, which will affect the efficiency of loading and unloading, assembly and transportation in the long term.
- the tooling is unstable and there is a risk of parts falling out: Insufficient air pressure leads to a decrease in clamping force, and heavy parts, surface oil stains, or center of gravity shift are prone to slipping, tilting, and even falling.
- vacuum gripping is unstable: Air leakage affects the vacuum generation efficiency, resulting in weak suction, slow pressure release after suction, alarm during transportation, or workpiece falling off.
- Load balancing exception: After the balance air circuit leaks, the workpiece will float, sink, hover unsteadily or the operation will feel heavy.
- Risk of safety protection malfunction or failure: Pressure switch, vacuum detection, limit valve, safety valve signals are abnormal, false alarms, false shutdowns or frequent protection actions occur.
- Component life is shortened and energy consumption increases: Frequent air replenishment of the air compressor will accelerate the wear of valves, seals, cylinders and vacuum generators.
02On-site inspection steps
- The first step is to observe the device status: Check whether the movement is slow, jittering, unstable in hovering, weak in clamping, or weak in vacuum gripping, and record the faulty workstation, movement and time.
- The second step is to do a safe uninstallation.: Place the workpiece in a stable position, confirm that the clamp is released or safely supported, then stop the machine and turn off the compressed-air supply, and release the residual pressure if necessary.
- The third step is to check the compressed-air supply pressure: Check whether the compressed-air supply pressure is within the required range of the equipment, and confirm whether the main compressed-air supply, filter pressure reducing valve, and branch pipelines are abnormal. The specific pressure is subject to the equipment nameplate, instructions or the requirements of the AUREK solution.
- Fourth Step: Inspect Air Lines and Fittings: Check section by section along the compressed-air supply inlet, valve group, actuator, and tooling end to see whether the pneumatic tubing is aged, flattened, bent, or broken, and whether the quick-connect connector is loose, dislodged, or poorly sealed.
- Fifth Step: Inspect the Vacuum Cups and Tooling End: Check whether the suction cup is aged, deformed, or cracked, and whether the surface of the workpiece is rough, holes, oily, or dusty; for clamping, check the jaws, cylinders, limits, and connectors.
- Step Six: Reset and Trial Run: After dealing with common air leakage points, conduct a trial operation under no load or low-risk conditions, and then gradually resume production after confirming that the action, pressure, vacuum gripping and alarm are normal.
03Air path abnormality checklist
| Symptom | Possible Causes | Check method | Recommended Action |
|---|---|---|---|
| Equipment response is sluggish | pneumatic tubing leaks, compressed-air supply pressure is insufficient, filter is clogged | Observe the pressure gauge, listen for air leakage, and check the pipelines | Deal with air leakage points, clean or replace filter elements |
| The manipulator hovers unstable | Abnormal load balance, air pressure fluctuation, valve group abnormality | Test the hovering state separately with no load and with load. | Shutdown inspection, if the balance system is involved, please contact the manufacturer. |
| The clamp is unstable | Loose joints, insufficient clamping cylinder pressure, and worn clamping jaws | Check the fixture air path, clamping action and mechanical connections | Tighten joints, replace worn parts, and handle them if necessary. |
| Vacuum suction cup is not strong enough | Vacuum leakage, aging suction cup, and workpiece surface not suitable for vacuum gripping | Check vacuum gauge, suction cup edge and workpiece surface | Replace the suction cup, clean the surface, and review the vacuum gripping plan |
| Frequent alarms or unexpected shutdowns | Abnormal pressure switch, abnormal safety valve, and pneumatic line fluctuations | View alarm location and pressure changes | It is not recommended to remove safety parts by yourself, you should contact a professional |
| Gas consumption increased significantly | Long-term air leakage in pipelines and poor joint sealing | After stopping the machine, listen to the sound or check with leak detection fluid. | Replace pneumatic tubing, fittings or seals |
| Workpiece floats or sinks | Balance pneumatic circuits leakage, load changes, and adjustment abnormalities | Observe load hovering and lifting trends | Stop using it and contact the manufacturer to check the load balancing system. |
04Daily prevention advice
Routine maintenance can be carried out from the aspects of "looking, listening, touching, and checking": check whether the pneumatic tubing is worn, bent, aged, and stressed; listen to see whether there is continuous air leakage during operation or pressure maintenance; feel whether the joints are loose and whether the pipeline is pulled; check whether the pressure gauge, vacuum gauge, filter pressure reducing valve, and alarm record are normal. For pneumatic tubing that frequently swing, rise and fall, or are close to the edge of the workpiece, additional fixing and anti-wear measures should be taken; for vacuum suction cups, regularly check the edges, elasticity, and sealing surfaces; for custom tooling, pay attention to the clamping mechanism, limiters, connecting bolts, and cylinder movements. It is recommended to establish inspection records and include compressed-air supply pressure, air leakage points, joint replacement, suction cup replacement, abnormal alarms, etc. into the equipment ledger.
Are there recurring problems with the air circuit?Send us the equipment model, fixture structure and fault symptoms, and AUREK can provide targeted maintenance and air path troubleshooting suggestions.
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