Cycle Time-Based Fault Detection and Localization in Pneumatic Drive Systems

Research output: Contribution to journalResearch articleContributedpeer-review

Contributors

Abstract

Compressed air ranks among the most expensive forms of energy. In recent decades, increased efforts have been made to enhance the overall energy efficiency of pneumatic actuator systems and develop reliable fault detection methods for preventing energy losses. However, most of the methods developed so far require additional sensors, resulting in extra costs, and/or are not applicable during machine operation, which leads to their limited use in the industry. This article introduces a cycle time-based method for detecting faults in pneumatic actuators through the use of proximity switches, enabling cost-effective monitoring in real time without the necessity of further sensors. A systematic analysis is conducted, expanding the current state of knowledge by detailing the influence of all potential leakage points on the movement times of a pneumatic drive and taking into account the different velocity control strategies (meter-out and meter-in) and operating points expressed via the pneumatic frequency ratio. Previously unassessed specifics of internal leakage, including the impact of pressure profiles and differences between differential cylinders and cylinder with equal piston areas, are also presented. The applicability of the proposed method and its detection limits in an industrial environment are examined using pneumatic assembly machines.

Details

Original languageEnglish
Article number447
Number of pages22
Journal Actuators : open access journal
Volume13 (2024)
Issue number11
Publication statusPublished - 7 Nov 2024
Peer-reviewedYes

External IDs

unpaywall 10.3390/act13110447
Scopus 85210431322

Keywords

Keywords

  • compressed air systems, condition monitoring, energy efficiency, energy loss, fault detection, friction, leakage, pneumatic actuators, pneumatics