INTRODUCTION TO EFFECTIVE MAINTENANCE FOR PNEUMATICS SYSTEMS

Pneumatic power is the power that is transmitted by pressurized/compressed air. This Effective Maintenance For Pneumatics Systems course provides maintenance personnel and production operators with the skills and knowledge necessary to carry out maintenance tasks on pneumatic control system as practiced in the industry.

Familiarization of both basic pneumatic components as well as their function and structure are learned and practiced in this course.

This hands-on training will allow the participants to understand electropneumatic functions, components, commission, and troubleshoot basic electro-pneumatic control system used in the industry.

KEY OBJECTIVES

• Knows the basic principles of compressed air generation, distributions and preparation.
• Understanding of Pneumatic basics
• Understand the need for safe isolation and be able to apply safe working practices when
  working with pneumatic systems
• Demonstrate relevant underpinning knowledge (units, pressure, forces, etc)
• Identify, inspect, adjust and replace
• Pneumatic valves (air and solenoid operated, sequence, directional control)
• Actuators (cylinders and rotary)
• Flow controls and quick exhausts
• Use visual indicators and manual overrides to check operation of components
• Carry out repairs to pneumatic systems, replace fittings, plastic pipe-work, etc
• Use pneumatic circuit drawings as an aid to systematic fault-finding
• Explain the function and use of 5/3 way solenoid valve.
  • Testing of solenoid valves
  • Insulation test
  • Continuity test
  • Voltage test

METHODOLOGY

• 30% Theory and 70% Practical.
• Practical exercises using Directional Control Valve to control single acting cylinder
• Practical exercise using Directional Control Valve to control double acting cylinder.
• Individual and team skills development
• Video presentations
• Simulation and Workstation training
• Structure of electro-pneumatic control system
• Design/wire/test using relay to perform latching/holding circuit.
• Practical design/wire/and test using relays and valves.

COURSE CONTENT

Module 1
Introduction

• Pneumatic theory
• Advantages of fluid power
• Transmission of forces through fluids
• Pascal’s law
• Force and pressure
• Computing force, pressure and area
• Multiplication of forces
• Differential areas
• Compressibility and expansion of gases (Boyle’s law/ Charles’s law)
• Work and energy

Module 2
Fundamental of Pneumatic Systems and Components distributions and preparation

• Pneumatic Components
• Compressors
• Filter, Regulator, Lubricator Unit
• Air control valves
• Quick exhaust valves
• Pneumatic actuators
• Role of service units
• Characteristics of pneumatic system
  • Properties compressed air
  • Advantages and disadvantages of compressed air
  • Structural and signal flow of pneumatic systems
• Simulation and Workstation training

Module 3
Pneumatic cylinders

• Sizing of cylinders and valves for projects
• Structure, function and application of single-acting and double-acting cylinders
• Calculating basic parameters
• Direct and indirect actuation
• Application and function of 3/2 and 5/2-way solenoid valves
• Single-acting cylinder
• Double-acting cylinder
• Start-up valve with filter control valve
• Manifold
• Plastic tubing
• Air pressure reservoir
• Simulation and Workstation training

Module 4
Maintenance and Troubleshooting of Pneumatics System

• Typical error patterns for pneumatic systems.
• Causes of compressed air loses, lower cylinder forces and slow pressure built-up.
• Part subject to wear and tear.
• Possible causes of failure on individual components.
• Understanding circuits and discerning any non-conformities
• Performing routine maintenance and safety regulation.
• Systematic troubleshooting and fault tracing procedure
• Simulation and Workstation training

Module 5
Preventive Maintenance

• Common wearing of parts in pneumatic components.
• Preventive maintenance of pneumatic systems.
• Sequential design with supplementary conditions.
• Systematic fault findings in complex pneumatic control system and correction.

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