3 Key Factors for Optimal Pneumatic System Performance

June 12, 2024
Agar sistem pneumatik bekerja dengan baik - Bawalaksana ID

Pneumatic systems have become indispensable to various industries due to their efficiency and cost-effectiveness. These systems rely on several crucial factors, such as air quality, pressure, and flow rate, to ensure smooth operation. 

Ignoring these factors can lead to system failure, resulting in significant losses in costly repairs and downtime. 

In automation systems, pneumatic systems are crucial in achieving effective and accurate equipment operation. However, to achieve optimal performance, it is essential to consider three critical factors:

  • The most vital components.
  • The implementation of best practices.
  • Solutions to technical issues that may arise. 

In this article, we will delve into these factors in-depth, providing valuable insights into how they impact the performance of pneumatic systems.

We will also offer practical solutions to technical problems that may arise, enabling you to plan, construct, and maintain pneumatic systems with precision and efficiency. 

By familiarizing yourself with these critical factors, you can ensure that your pneumatic systems operate efficiently and achieve optimal performance.

Vital Components in the Proper Functioning of a Pneumatic System

It is essential to adhere to specific guidelines to achieve optimal functionality of the pneumatic system. These guidelines are as follows:

  • Supply of high-quality, clean, and dry air
  • Properly installed pneumatic pipe or hose network
  • Implementation of all components according to industry standards
  • Correct air pressure adjustment according to system requirements
  • Lubrication of moving components
  • Utilization of an electric controller for operation and automation
  • Regular maintenance to prevent damage and leakage
  • Use of safety equipment to reduce the risk of accidents
  • Adequate knowledge and training

In the next section, we will provide an explanation related to all the points mentioned above. In this explanation, we group them into three crucial factors for the pneumatic system to work properly.

Industrial solenoid valve for liquid, oil, air, pneumatic, hydraulic pipe line machine - Komponen sistem pneumatik
Several components are required in a pneumatic system.

First Factor: Paying Attention to Essential Components in Pneumatic Systems

Building efficient pneumatic systems, including essential components, is crucial to ensure their smooth functioning. Some of these components comprise the following:

  • Air Compressor
  • Refrigerated Air Dryer
  • Air Reservoir Tank
  • Air Service Unit
  • Regulator
  • Pneumatic Valve
  • Pneumatic Tubes
  • Fittings
  • Solenoid Valve
  • Pneumatic Cylinder
  • Others

It is imperative to have a comprehensive understanding of the components of a pneumatic system, as each component plays a vital role in determining the overall quality of system performance. 

A previous article titled “What are the components of a pneumatic system that need to be known?” comprehensively explains the functions and benefits of each component. 

It is essential to ensure that the pneumatic system comprises all the necessary components to ensure optimal performance, safety, and longevity of the devices. Therefore, selecting the appropriate components for your pneumatic system is recommended to guarantee its smooth and reliable operation.

Second Factor: Implementation of Pneumatic System According to Best Practice 

Pneumatic systems are widely used in the industry for automation systems due to their popularity as a cost-effective choice for systems that require mechanical motion. 

These systems can perform components transfer, positioning or clamping, and other essential functions. However, they may face issues and problems if not correctly designed or implemented. 

Therefore, it is highly recommended for your company to be aware of the possible incidents that can occur to operate the system effectively:

  • Setting the air pressure that is too low or variable
  • Improper use of air flow controllers
  • Ignoring the decrease in cylinder performance when activating the system.
  • Allowing pneumatic cylinders not properly to exhaust air
  • Ignoring inconsistent or too-slow pneumatic cylinder speed
  • Not paying attention to cylinder movement that is too harsh or not smooth
  • The Solenoid Valve is locked, stuck, or even leaking

The following suggestions can assist you in enhancing the performance of your pneumatic system as an additional guide:

Consistent and Adequate Air Supply 

Air plays a crucial role in pneumatic systems as it needs to be clean, dry, and free from contaminants for smooth operation and to prevent any harm to equipment components.

To ensure optimal performance and maintain the quality of air used in these systems, it is essential to have a reliable and consistent air supply, along with advanced filtration systems. These measures improve the efficiency of pneumatic systems and prolong their lifespan.

Safety and Security Features 

It’s important to note that pneumatic systems must have safety features installed to ensure smooth and safe operation. These features include Manual Lockable Air Dump Valves and Electric Soft-Start Air Dump Valves. These valves are vital in stopping the system in emergencies and preventing potential damage or harm.

Proper Size and Industry Standard Compliance 

The selection of components with the right size contributes to the smooth operation of pneumatic systems. As is known, various pneumatic components are available in multiple sizes and types, depending on their application in the industry—for example, air dryers, compressors, pneumatic hoses, fittings, and valves. 

The right size will result in effective operation in terms of operational costs and energy consumption. On the other hand, selecting the wrong size and type can lead your system to unwanted problems. 

Lubrication in Pneumatic Components 

Lubrication in pneumatic systems is essential for keeping them running smoothly and efficiently. It involves applying a substance to moving parts to reduce friction and wear.

Why Lubrication is Important?

  • Reduction of Friction: Lubricants reduce friction between moving parts, which helps them last longer and lowers maintenance needs.
  • Heat Dissipation: Lubrication helps to dissipate heat, preventing damage from overheating.
  • Sealing and Protection: Lubricants protect components from moisture, corrosion, and contamination, maintaining the system’s integrity.

Using Electric Controller 

Pneumatic systems require an Electric Controller to improve performance and efficiency in various applications. The involvement of this device varies depending on the industry. It can range from simple switches and relays to involving PLC (Programmable Logic Controller) to automate operations. 

Preventive Maintenance 

Preventive maintenance can include regularly scheduled actions to prevent damage, system failure, or downtime. By doing so, your company can achieve higher efficiency levels and use equipment with a longer lifespan. 

Knowledge and training 

Training is crucial for providing operators and engineers in your company with adequate knowledge of pneumatic systems in line with industry standards. Knowledge and training are essential when implementing pneumatic systems to ensure they function efficiently and safely.

Here are some reasons why knowledge and training are essential when implementing pneumatic systems:

Understanding of Pneumatic Systems: Training provides operators and engineers with a comprehensive knowledge of pneumatic systems, including components, working principles, and maintenance procedures. This allows them to familiarize themselves with industry standards, best practices, and safety protocols.

Efficient Operation: Proper knowledge and training enable operators to operate pneumatic systems effectively, improving productivity and reducing downtime. Understanding the intricacies of pneumatic systems allows for quick troubleshooting and problem resolution, minimizing disruptions.

Safety: Comprehensive training emphasizes safety protocols and guidelines, reducing the risk of accidents and ensuring the well-being of personnel working with pneumatic systems. Knowledge of safety measures also contributes to protecting equipment and the work environment.

Optimal Maintenance: Training equips personnel with the skills to conduct regular maintenance, vital for the longevity and performance of pneumatic systems. Proper maintenance, guided by knowledge and training, helps prevent breakdowns and extends the lifespan of the equipment.

Compliance with Regulations: Adequate knowledge and training ensure that the implementation and operation of pneumatic systems align with industry regulations and standards, avoiding potential legal issues.

Implementasi sistem pneumatik dengan vacuum suckers di manufacture phone factory
Implementation of pneumatic system with vacuum suckers in a phone manufacturing factory.

Now that you comprehend the significance of adhering to best practices while implementing pneumatic systems, you are one step closer to achieving greatness.

Although investing in such systems is a huge decision, with the assistance of experienced expert teams, you can guarantee that each component performs optimally.

By doing so, you will become a part of Industry 4.0 and play a vital role in upholding industry standards and regulations. Therefore, take a step towards progress and make a difference today.

To know more about best practices in implementing pneumatic systems, please visit another article on Preventing Downtime with Implementation of Pneumatic Systems According to Best Practice.

Why Involving Experienced Team Members is Important?

Running a business can be challenging at times, so it’s crucial to have a team of experienced members to help you anticipate and tackle any issues that may arise. This can save you from unexpected situations that might cause downtime or system failures.

At PT. Bawalaksana Central Industrial, we take pride in being an official supplier of Industrial Automation equipment and having a professional team with years of experience, primarily to support your company when implementing Pneumatic System Automation. We realize the importance of experts offering valuable assistance and consultation.

If you need help from our experts or want to consult with us, please don’t hesitate to contact us. We’re always happy to help. 

Feel free to submit any questions or consultation requests through our platform, and we’ll get back to you as soon as possible.

Third Factor: Understanding Common Problems in Pneumatic Systems and Their Solutions

Pneumatic systems offer numerous advantages that can significantly enhance a company’s productivity. However, it’s essential to acknowledge that these systems can encounter specific issues that, if neglected, may disrupt their performance and efficiency. 

Fortunately, the problems associated with pneumatic systems are generally simple, especially when anticipated and addressed by a competent engineering team. 

In this section, we will delve into some common problems frequently encountered in pneumatic systems, including:

Inconsistent Air Pressure

Inconsistent air pressure is one of the most significant challenges pneumatic systems face. It can lead to unpredictable and irregular movements of pneumatic cylinders, affecting the system’s overall performance. Therefore, it is crucial to design the system correctly and equip it with suitable air flow controls to mitigate this issue.

One of the significant problems caused by inconsistent air pressure is challenging speed control. When air pressure varies, it can affect the speed of the pneumatic cylinder, making it difficult to control and regulate. This can result in a decrease in productivity and efficiency levels.

Additionally, inconsistent air pressure can compromise precision levels, which can be a critical concern in applications requiring high accuracy levels. Even slight variations in air pressure can affect the system’s accuracy, leading to errors and inconsistencies.

To proactively address these concerns, utilizing high-quality devices obtained from authorized distributors or reputable industrial equipment suppliers is advisable. These devices are designed to withstand varying air pressure levels and maintain consistent performance, ensuring optimal system performance and longevity.

Authorized Distributor of Mebra Plastic - Pneumatic Tubes Products - Header
Pneumatic hose from Mebra Plastik Italia.

Cylinder Speed Issues

Various factors can cause cylinder speed issues in a pneumatic system. These factors may include low air pressure, using oversized cylinders, damaged or undersized pneumatic hoses, or malfunctioning solenoid valves. To resolve these issues, it is essential to adjust the components accordingly. Here are some recommended measures to address these cylinder speed issues:

Check Air Pressure

Make sure that the air pressure entering the pneumatic system is sufficient. Low pressure can cause the cylinder to move slowly. Consider using a pressure regulator to adjust the air pressure according to the recommended specifications.

Evaluate Cylinder Size

If the cylinder size is too large for the application, it can result in inefficient speed. This typically occurs when the compressor capacity is insufficient. It is advisable to use a cylinder with the appropriate diameter that matches the load to be moved to enhance speed.

Cleaning and Maintenance

Remember that dust or dirt in the pneumatic system can slow down cylinder operation. Therefore, it’s essential to perform regular maintenance and clean or replace components that have worn out.

By paying attention to these factors, you can improve the speed of your cylinders and enhance the overall efficiency of the components in your pneumatic system.

Leakage and Noise

Leakage and noise in pneumatic systems can be significant issues, leading to higher operational expenses. It is crucial to note that a properly designed and well-maintained pneumatic system typically operates smoothly and quietly.

What Causes Noise in Pneumatic Systems?

Noise can occur in pneumatic cylinders if the bearings at the base of the pneumatic cylinder are not sufficiently adequate when the stroke reaches the stop point.

Regularly replacing the cylinder bearings in your machinery can significantly reduce the noise levels and prevent excessive wear and tear. This proactive step ensures the longevity of your machinery and increases its efficiency, leading to better performance and output.

Tips for Dealing with Leaks

Leakage in pneumatic systems can be caused by various factors, including:

  • Worn-out valves
  • Cracked or broken pneumatic hoses
  • Poorly installed fittings
  • Damaged connectors
  • And others

It is important to note that detecting leaks in pneumatic systems can be challenging. This can lead to unnoticed pressure drops, which in turn can cause a decrease in system performance.

Pneumatic system leaks can lead to a significant increase in production costs, up to $38,776

According to the US Department of Energy, even a small leak of just 1/4″ (6.35 mm) in a pressurized air line can have significant financial implications, potentially increasing production costs by up to $38,776 per year, calculated through cost savings formulas. It’s crucial to recognize that unaddressed leaks in the pressurized air system can result in the wastage of 20%-30% of the output generated by the air compressor.

Kebocoran sistem udara bertekanan dapat menyebabkan pembengkakan cost hingga $38,776

These issues can precipitate a range of other problems, including:

  • Fluctuations in pressure within the system can cause components to operate inefficiently and consequently impact production quantities.
  • Increased demand for compressor capacity leads to higher costs than necessary.
  • Reduced lifespan and heightened maintenance costs, including those associated with compressor packages.

What do we do when a leak occurs in the pneumatic system?

The most effective method for identifying leaks is an Ultrasonic Acoustic Detector, renowned for detecting high-frequency hissing sounds commonly associated with air leaks. Utilizing this device allows for precise pinpointing of leak locations, facilitating efficient and timely repairs.

To maintain optimal performance and prevent potential issues, it is advisable to take the following precautions, even in the absence of a pneumatic system leak:

  • Conduct routine inspections to ensure all components are functioning correctly and leak-free.
  • Pay particular attention to pneumatic hoses, fittings, and connectors, checking for signs of damage, wear, or looseness.
  • Thoroughly investigate any suspicious sounds that may indicate leaks originating from components. Then, inspect all valves to ensure correct installation.
  • Upon identifying the source of a leak, promptly perform repairs or replace damaged components to prevent further complications in the future.
Robotic linear and rotary pneumatic - Faktor Penting Agar Sistem Pneumatik Bekerja Dengan Baik
Implementing Pneumatic Systems in Industrial Automation

Why is the implementation of pneumatic systems in the industry highly beneficial?

Pneumatic systems are popular in numerous industrial settings due to their exceptional strength, speed, accuracy, cost-effectiveness, straightforward design, easy installation, low maintenance, and long-lasting durability. 

These systems can operate efficiently even in harsh environments with high temperatures or dust. Given their robustness, many industries can confidently implement pneumatic systems in challenging locations. They find widespread use in several industrial sectors, including but not limited to:

  • Manufacturing
  • Construction
  • Aerospace
  • Medical
  • Textile
  • Rail transport
  • Oil and gas
  • Printing machines
  • Pulp and paper
  • Car washing
  • Industrial robots
  • Automotive industry
  • Plastic and packaging
  • Industrial automation systems
  • Chemical processing
  • Food and beverage

Designing a pneumatic system requires careful consideration of various aspects such as the location, infrastructure, and component selection. We understand the importance of optimizing the Pneumatic System Automation in your company and suggest focusing on common issues that may arise and implementing best practices. 

By taking care of these factors, you can ensure that the pneumatic system in your company will work efficiently and effectively, providing numerous benefits. Whether you need help with planning, implementation, or system rejuvenation, our Sales Engineer team is always here to assist you. 

We can ensure that your company’s pneumatic system runs smoothly, helping you save time and money while increasing productivity. Don’t hesitate to contact us for assistance; we’ll gladly support you.


This article was written in collaboration with Romanta Pinrih Linuwih, an expert in Pneumatic Automation Systems, to ensure accuracy and high quality.


REFERENCES

Phillips, P. (2015, October 16). Guidelines to Successful Pneumatic Systems. Library.Automationdirect.com. Retrieved January 11, 2024, from https://library.automationdirect.com/guidelines-successful-pneumatic-systems/

Energy Tips – Compressed Air. (2004). Industrial Technologies Program. https://www.energy.gov/sites/prod/files/2014/05/f16/compressed_air3.pdf

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