Troubleshooting and fault diagnosis in fluid power systems

Troubleshooting in Fluid Power Systems

Troubleshooting is a systematic approach to diagnosing the cause of a fault or problem in a fluid power system.
A thorough understanding of fluid power principles and the mechanics of the system in question is essential for effective troubleshooting.
The troubleshooting process often involves identifying the symptom, isolating the issue (which can be hydraulic or pneumatic in nature), and then repairing the component that caused the fault.
Effective problem solving frequently involves both proactive maintenance—regularly checking the system for wear and performance—and reactive maintenance—responding to problems as they occur.

Identifying Faults or Problems

Faults in fluid power systems are often first identified through symptoms such as abnormal noise, unexpected motion, system overheating or reduced efficiency.
Observation, along with the use of pressure gauges, flow meters, temperature sensors and other diagnostic devices, can help identify issues like internal leakage, external leakage, incorrect pressure or temperature, and mismatch between input signal and output motion.
For example, a sudden change in the noise produced by the pump may suggest cavitation or other problems, while an increase in temperature could indicate excessive friction or inefficient operation.

Common Faults in Fluid Power Systems

Cavitation is a common hydraulic system fault caused by the formation and subsequent collapse of vapour pockets in a high speed moving liquid. It can lead to damage of system components.
Aeration refers to air entering the system, which is another common issue that can cause the pump to make a loud noise or the fluid to appear cloudy.
Valve failure, shown by a loss of control or inability to direct the fluid, can be caused by wear, contamination or incorrect assembly.
Problems with the actuator, like a cylinder moving too slow or not at all, might indicate issues with the load, friction or seal integrity.
Pump failure could be due to wear, incorrect installation, or other part failure like ailing bearings.

Solving Problems and Faults

Once the fault is diagnosed, the next step often involves repairing or replacing the affected component.
Good maintenance practices, such as keeping the fluid clean and free from contamination, can help prevent many problems.
Many common faults can be avoided by following manufacturer’s installation and operation guidelines, maintaining proper fluid level, and regularly checking for signs of wear or damage.
Always remember to follow best safety practices during any maintenance or troubleshooting work. Use personal protective equipment and ensure the system is safely shut down before starting work.