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  • Filtration Principles of Pneumatic and Hydraulic Systems: A Comparison Study

    Filtration Principles of Pneumatic and Hydraulic Systems: A Comparison Study

    This article is the third part of the following three-part series of articles:

    Filtration and Drying Principles in Pneumatic Systems

    Filtration Principles in Hydraulic Systems

    Filtration Principles of Pneumatic and Hydraulic Systems: A Comparison Study

    The filtration principles of pneumatic and hydraulic systems were given in the previous articles. The third part of the three-part series of articles on filtration principles in fluid power systems attempts to make a comparison of the filtration principles, as given in Table 1. A comparative study of the filtration principles would bring out the essential similarities as well as differences in the filtration principles and would provide an overall view of the subject matter.

    Table 1 | A comparison of the filtration principles in pneumatic and hydraulic systems

    ParameterPneumaticsHydraulics
    Medium of energy transferCompressed airOil
    ContaminantsParticles, moisture, oil, +Particles, chemical contaminants, moisture, air, +
    Effect of contaminantsAbrade surfaces
    Corrode internal parts
    Reduce functionality and service life of components    		Abrade surfaces
    Corrode internal parts
    Reduce service life of oil
    Cleanliness standardsISO8573ISO 11171 & ISO4406
    NAS1638
    SAE AS4059
    Particle removalFiltersFilters, Magnets
    Moisture removalDryers, FiltersVacuum dehydrator
    Oil (air) removalCoalescing filters
    Adsorption filters    		Air bleeds
    Diffuser (Baffle screen)
    Filter typesGeneral purpose filters
    Coalescing filters
    Adsorption filters    		Surface filters/ Depth filters
    Cartridge type/ spin-on
    Inline filters
    In-tank filters
    Filter mediaSintered bronze/ polyethylene
    Borosilicate glass microfibres
    Activated carbon    		Wire mesh
    Paper
    Synthetic
    Filter locationsIntake
    Mainline
    Service line    		Suction side
    Pressure side
    Return-line
    Offline

    Joji Parambath

    Author, Fluid Power Educational Series Books

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    Pneumatic and Hydraulic Books authored by Joji Parambath

    37 books in Paperback and Kindle eBook versions on the subjects of Pneumatics and Hydraulics, authored by Joji Parambath, have been published under Fluid Power Educational Series. Joji Parambath is a trainer in the field of Pneumatics, Hydraulics, and PLC, for over 25 years. All the books are available at Amazon marketplaces.

    These books deal with pneumatic system components and circuits. The fundamentals required to understand the core topics are given initially. These books describe the topics on compressed air generation and contamination control, pneumatic actuators, and control valves, in detail. Further, these books present the maintenance, troubleshooting, and safety aspects of pneumatic systems. Many single-actuator pneumatic circuits are given in multiple positions. Many critical positions of pneumatic single-actuator circuits are given to make the reader understand the control circuits easily.

    These textbooks deal with the components and circuits of hydraulic systems. The fundamentals required to understand the core topics are given initially. The book describes the topics on hydraulic fluids, filters, power packs (reservoirs, pumps, pressure relief valves) hydraulic actuators, directional control valves, flow control valves, pressure control valves, fluid conductors, and accumulators, in detail. Further, the book presents the maintenance, troubleshooting, and safety aspects of hydraulic systems.

    These books explain the basic principles of hydrostatic transmissions. The concepts of open-circuit and closed-circuit HSTs are explained in the book. The topics also include configurations, advantages and disadvantages, and applications of HSTs.

    These books enlighten the details of components required for load sensing systems. The operation of load sensing systems in their various operating modes is described in a simplified manner.

    The book ‘Electro-hydraulic proportional valves’ explores the technology used in proportional valves. The book also describes the construction of electro-hydraulic proportional valve systems, the details of various types of control elements, characteristics, and applications of proportional valve systems.

    The book ‘Electro-hydraulic servo valves’ describes the technology used in state-of-the-art servo valves. The book also describes the construction of electro-hydraulic servo valve systems, the details of various types of control elements, and the applications and characteristics of servo valve systems.

    These books explain the functioning of solenoid valves and various electrical control components such as pushbuttons, electro-magnetic relays, limit switches, reed switches, proximity sensors, electronic timers, and counters. The development of many typical single-actuator and multiple-actuator electro-pneumatic and electro-hydraulic circuits are also separately explained in these books. Many circuits are given in multiple positions for a quick understanding of the working of each circuit.

    And many more ….

  • Maintenance of Pneumatic Systems

    As you are aware, a pneumatic system is an interconnection of various components such a compressor, actuators, control valves, and other elements using fluid conductors. The operation of the pneumatic system is affected by the presence of heat, dust, moisture, leaks, loose bolts, and misalignment in the system. Lack of regular maintenance may result in the premature wear of moving parts, the loss of air and associated pressure drops, and increased downtime of pneumatic components. Therefore, a good preventive maintenance program must be in place for removing the harmful elements from the system from time to time, and usually as per a checklist. In general, maintenance includes the following closely-related activities: (1) Visual inspection, (2) Servicing, (3) Examination, and (4) Overhaul.

    Requirements for Preventive Maintenance

    The most general requirements of preventive maintenance are as follows: (1) Know the machine, (2) Understand and follow the best maintenance practices, (3) Compile a maintenance checklist, (4) Follow instruction manual, (5) Ensure safety, and (6) Stock spares.

    Concern for Safety

    The safety of personnel and equipment should always be kept in mind while carrying out routine maintenance activities. Safety can be built into a pneumatic system by incorporating interlocks, power-failure locks, and an emergency shutdown feature. Though the responsibility of building safety into a machine rests with the manufacturer of the machine, every technician should observe and practice relevant safety regulations. Further, every maintenance technician should make a serious attempt to know the hazards involved in his/her occupation.

    Activities for Good Maintenance during the Design Phase

    The planning for the good maintenance of a pneumatic system begins right from the design stage of the system. That means, the design must facilitate easy maintenance and the efficient removal of contaminants. Further, it is better to plan and design a pneumatic system with correctly-sized and inherently-safe components for its reliability and long service life.

    Activities for Good Maintenance during Installation

    Additionally, it is required to install a machine in such a way that there is ample space for the operation and maintenance of the machine. It is also essential to provide adequate lighting and a clean environment. The service indicators must be easily visible, and service points must be accessible without any difficulty.

    Maintenance, Troubleshooting and Safety in Pneumatic Systems

    Joji Parambath

    Details of many other books under Fluid Power Educational Series from the same author can be accessed from:

    https://jojibooks.com

    Removal of Heat and Solid Contaminants

    It is essential to maintain various conditioning devices, like coolers, filters, dryers, and lubricators, at regular intervals, for the removal of heat and other harmful contaminants. The routine maintenance activities generally include cleaning, visual inspection, running checks, and servicing of filters, lubricators, and coolers. The reason for any abnormal noises in the system should be investigated immediately.

    Plugging Leaks

    An essential requirement of any pneumatic system is to stop leakage, as expensive leaks cost big money. Application of soapy water or commercially available leak detecting liquids, like aerosol sprays, on suspected joints, might reveal the presence of leaks. An ultrasonic leak detection instrument can also be used to locate leakages.

    Mounting of Components / Machines

    The mounting bolts of components must be torqued correctly. Further, every prime mover must be perfectly aligned with the associated load part to reduce undue stress on components, seals, and bearings. A maintenance technician should check for any vibration, loose bolts, or misalignment of components in a system.

    Joji Parambath

    https://jojibooks.com

    Fluid Power Educational Series Books

    Concept-oriented | Simple language | Vast coverage of topics | Low priced

  • Design of Pneumatic Systems

    Textbook on ‘Design of Pneumatic Systems in the SI Units’

    By Joji Parambath

    The book explains the design aspects of pneumatic systems systematically. The book also presents many typical examples of designing pneumatic systems using the SI units.

    Textbook on ‘Design Concepts in Pneumatic Systems in the English Units

    Please click on the image links to go to the Amazon Website

    A prerequisite for designing a pneumatic system is the knowledge of the functions, parameters, and specifications of the critical components needed for the power part, control part, and compressed air network of the system. A pneumatic system must be designed to meet all the functional requirements of an application safely and efficiently. It must be economical and straightforward.

    The design of a pneumatic system involves the determination of the force and speed requirements of all actuators in the system and finding the sequence of operations.

    Next, select and size of components, determine the system pressure level and find the average air consumption rate of all actuators, including cylinders, air motors, air-operated tools, and vacuum equipment.

    Next, select a compressor, receiver tank, and drive motor with sufficient delivery rate to meet the peak air consumption rate of all actuators and tools. Draw the important compressor specification parameters such as the drive motor power, drive speed, pressure rating, number of compression stages, and the operating voltage.

    After that, select and draw the specifications of components such as aftercooler, mainline filter, dryer(s), FRL unit(s), and control valves, based on the flow rate.

    Then, design the mainline and distribution conductor system to keep the pressure drop across the conductor system to a permissible limit. The selection of pipe size is governed by the delivery volume, required pipe length, operating pressure and the permissible pressure drop.

    Note: Five sample design problems are presented in the textbook to highlight the essential design steps. Sure, you will be greatly benefitted.

    Joji Parambath

    Director

    Fluidsys Training Centre Pvt Ltd

    Bangalore, India

    https://fluidsys.org