Exercise 12: Eliminating a fault on the pallet loading station Objective 1, Tobe able to identify and eliminate faults in simple electro-pneumatic control systems. Problem definition The pallet loading station stops during continuous operation. A fault has occurred and must be eliminated. Thereafter the pallet loading station is to be re-started. Parameters + Only one fault has occurred Project task 1. Describe the behaviour of the control system. Compare this with the correct control system behaviour. Use the displacement-step diagram to assist you. 2. Localise potential causes of the fault with the help of the pneumatic and electrical circuit, agrams. 3, Find the fault in the control system and eliminate it. 4, Re-start the control system, 93 McereeeuCTIVE U8, Scanned with CamScannerPallet loading station 1. Glinder 11 is to advance if pushbutton S1 is pressed. This causes a single package reach its loading point thereby actuating sensor 182. 2. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the package onto the pallet 3, IF 2B2 is actuated and $1 unactuated, cylinder 1A1 retracts, 1B2 is no longer actuate gylinder 241 retracts. Consequently the overall sequence is: 1A1+ 2A1+ 1A1-2A1- — MCELLME ELECTIVE 1 LAB Scanned with CamScannerFault finding in simple electro-pneumatic circuits The following fault occurs in the circuit shown below. ‘The piston rod of cylinder 1A1 and the piston rod of cylinder 241 advance and remain in the forward end position. = Describe what the potential causes of the fault could be. Pneumatic circuit (aee ang el eyiner “AL olgcteacersen gouly | [ine ilerropien in eorreat_poth 26 aaa Line okeruption In sigpcl line eprnser2jcretpal® 25, “aeeaaares friplion I EGRING wire ey TMZ, curreat poTR, vale | eine int on hn earthing wit ep Felayk2, curren? pathy AEE AERO corer poth 7, pppine oe eta oles payne 9g {ML ee-aupply lide op elay contac tater valve Zou! 1h —| 95 Scanned with CamScannerElectrical circuit diagram { entrant [eer uty, 11M? 202 ep 2At_naldjuctee | ing ee Menieor 983) 4) cylinder (441 maldjupded | 282 sensor mold justed | [ve Scanned with CamScanner‘A cable break occurs at the areas marked in the circuit shown below. = Describe what the effects of a cable break at these respective points are on the functioning of the circuit. Blectrical circuit diagram | x | | | x x | | | Pe ecieat Fatloy Raad WR Siren pane? aber ee ay eta = Finan ted of gfinder el doce. nel mene’ into. ihe “poruatS) ced Fie cl Wd chica Pole Wind ey ‘Fisker rtd ep cplinder odvoncer, fencer 1a! is acuated <*> Prefer re Gitder tall meee fade tee peescrd tnd poodtenscenicy BBS fy setae 3 Reloy Het ie act eneyqiepd of Relay cenagt in curred? patti deh SS Atha Sea Sd pie 28 en ad cet Stapenee Seles tigead S*Rcyen Ped obltadee? ta} Mwai eieten or wey Spine Pad temotn nednactel Pred or cylindé tl Odvances ,sensee THIK actuated *? pisten ead CSaO recta Est checgeed due 7 Scanned with CamScannerFault finding: Determining the required status ~ Create the displacement:step diagram withthe help of the documentation given out. Displacement-step diagram Eee T_T EEE | | | | Sorel T CI | Ly os { | | 4 po en t | 4 7 1 | Poe { tt Mcrae neve U8 8 Scanned with CamScannerFault finding: Set-point/actual comparison Determine the ACTUAL status of the system with the help of the following documentation: + Positional sketch with problem description * Graphic representation = Ifthe correct function is not given (REFERENCE/ACTUAL comparison), clearly mark the area in the diagram where the fault occurs. Displacement-step diagram Scanned with CamScannerScanned with CamScannerFault finding: Definition of faults — pneumatics (Once you have established the ACTUAL status of the system, consider what the causes of the faults could be. In which pneumatic tubing connections could the fault occur? Enter all the possibilities and indicate components at the start and end of the tubing connection in order to ensure clear identification. Potential faults Fotentiat autt | Tabing connection to | su tot —<—<—<$< $$ | 2 oF vowe Wwe Mop vatwe tye J Log valve 2Y2 1 ap voiwe 2va tine 4 of valve Wt | 2 op valve IV? tol Scanned with CamScannerFault finding: Definition of faults - electrics ‘Once you have established the ACTUAL status of the system, consider what the causes of the faults could be. In which current paths could the fault be located? What is the function of the current path? Enter all the possibilities, Potential faults Potentiat fact | Carvent path Ne. | Function of cutent path Reiualee relay KA to chang: contact K2 fo energised 1M2 dRebeescaieeb cashes apeeiebicasenseoaest | changeover comad 1 energize iM? | Line for pushbutton to actuate relay | Ks | "| Rduates reioy #7 70 close “ehongecer contoct KI $0 enengizes Lit Ling por chongeever contoct istand ene ange ever ei hat 102 Scanned with CamScannerFault finding: Localisation of faults - pneumatics Investigate the potential causes of errors you have found in the pneumatics, = Use the same fault numbering that you have used for the worksheet ‘Definition of faults ~ pneumatic * Document the procedure used to investigate the tubing connections. + Enter the results of your investigation, Measuring and test protocol Compressed om fer Sop valve vt Lop valve 2 | Tubing tne break oP ery ‘depressed air ach 1 2 Beg volve 2V2_ top vole 2V4 | tubing ne brea eamresecd ot oa Vconpressed aie net ine Yqvalve wt Zep valve 1V7 Break Line 3 [tine gvane wt fer vale 11 rv wie cee we nese +8 103 Scanned with CamScannerFault finding: Localisation of faults Investigate the potential error causes you have found, ‘+ Use the same fault numbering that you have used in the worksheet ‘Definition of faults - electrics’. + Document the procedure you have used to check the line connection, ~ Enter the result of the investigation. Measuring and test protocol —S— [rear eee a mon EE i 1 Break in apay elm onder a 1 {4 BSP IG eon loans 2 7 | PRok suply Wo he LP aceon | | lr tentocwiend n { reat I suppy We Taam BAIR oan HER AER eee eh see Break In Corthing [REG IM adv oneet aE Ee COND play tat nea 5 8 | | ercax in earthing O54 AT odvoncee ard | vine gait TA ema ican ‘Once you have localised the failure location, your procedure for the elimination of the fauit must ‘be documented on this worksheet Describe each of the steps carried out in deta tum the machine opp in ceder 2 avoid sudden surge oF ckeicly Fe body Get new wiring er Jubing Connection cempenenie renee the _machioe is ofp; proceed fe Ihe poults identified cheese fhe ccnnecting wites where thr pauls ert ident Tura Phe machine on to check the poulled ines ore peed 104 Scanned with CamScannerNote In the event of the system not fulfilling the intended function, return to the first worksheet and repeat the fault finding. ‘Ask for new worksheet s to do so. Fault finding: Re-starting (Once you have identified, localised and eliminated the fault re-start the system in accordance with the required status, Reset the specified required times Briefly document the procedure followed in note form. Hep 4) ovcened Pe naw preonane toppy pent puch the 70" pipeline ond conpressice 1 Disconnect all preumatic input hae “Drain the rendensate lush eal he echfominonle 03 lubricater Ui? (FRU + Bags Ditrenned PRC tubps eet nicaler oad pil anmtgh a manual evertide zcenned ti + tperale “step WF getsoters s Repioce Tubings ip dary Cheek red cols ey the acluaice per only crath formation * Remeve dust porhels Re-greae oll he Lubecanes ee eee ee eC ee «lubricate dhe guides cp the guided drive Scanned with CamScanner