Workshop on Industrial Hydraulics & Pneumatics

Hydraulic Theory, Maintenance & Trouble-shooting

Course Outline

Module 1

• Standards for equipment and circuit diagram representation
• Design and function of hydraulic power supply systems
• Physical principles
• Measurement of volumetric flow rate, pressure and temperature as an aid to troubleshooting
• Hardware technology and characteristic data for valves and actuators
• Reading and interpreting basic hydraulic circuit diagrams for direction, speed, pressure and position

Module 2

• Standards and safety regulations
• Design and function of hydraulic power supply systems
• Design and function of hydraulic valves for controlling direction, speed, position and force
• Hydraulic drives for linear and rotary movements
• Electric signal control for hydraulic power section with switching solenoid and proportional solenoid interfaces
• Synchronised controls, valve fittings, hydraulic reservoir circuits
• Introduction to proportional technology using a setpoint-valve card, amplifier card and proportional valve
• Maintenance, inspection, scheduled and fault-related repairs on hydraulic systems
• Systematic troubleshooting, damage analysis and weakness elimination
• Intensive practical training involving design of control systems based on circuit diagrams, commissioning and testing

Module 3

• Basic principles of proportional hydraulics
• Design, function and characteristics data for proportional, directional control, pressure and flow control valves
• Generation of target values (analogue and digital)
• Adaptation of amplifier electronics to required conditions
• Development and interpretation of proportional hydraulic circuit diagrams
• Intensive practical training involving design based on circuit diagram and adjusting parameters for optimum commissioning
• Instructions for maintenance, troubleshooting and commissioning
• Introduction to servo valve technology and control
• Proportional valves in open control loop systems, control valves in closed control loops
• Current standards and safety regulations for practical operation and exercises

Module 4

• Hydraulic equipment maintenance - why it’s so important
• Maintaining fluid cleanliness
• Maintaining fluid temperature and viscosity within optimum limits
• Maintaining hydraulic system settings to manufacturers’ specifications
• Scheduling component change-outs before they fail
• Following the correct commissioning prodedures
• Conducting failure analysis
• The true cost of hydraulic fluid leaks
• Fluid contamination and dealing with water in hydraulic fluid
• Troubleshooting basics and how to avoid costly mistakes
• Symptoms of common hydraulic problems and their causes
• Locating internal leakage
• Fundamentals of hydraulic component and cylinder repair

Pneumatics Theory, Maintenance & Trouble-shooting

Course Outline

Module 1

• Objectives of low cost automation
• Basic principles of compressed air supply, production, preparation and distribution
• Power section devices (Linear and rotary actuators)
• Use of directional control valve, flow control, pressure and time control valves and sensorsStructure and function of pneumatic devices and valves
• Basic logic functions and their application
• Symbolic representation of devices and standards (ISO 1219)Systematic design of circuit diagrams
• Reading pneumatic circuit diagrams
• Operating modes in pneumatic control systems
• Safety regulations and valid industrial standards
• Typical industrial circuits
• Identifying and eliminating faults

Module 2

• Pneumatic Symbols and Standards
• Pneumatic power generation, preparation and distribution
• Design, function and identification of pneumatic components
• Reconstruction and reading of pneumatic circuits
• Reviewing, completing and using machine documentation
• Developing and applying troubleshooting strategies
• Optimising systems using fault documentation
• Learning and applying safety regulations and valid standards

Module 3

• Basic Principles of compressed air technology, production, preparation and distribution (Review)
• Power section devices and actuators, (specific application) Bellows, Rodless, rotary & Impact cylinders, Pulse Ejectors, Grippers
• Valves and basic logic funcions (specific application) Counters, Timers, Two Hand and binary control
• Positioning, open and closed loop
• Sequence, and sequence stepper control
• Vacuum technology
• Low pressure pneumatics (air sensors and amplifiers)
• Emergency Controls (soft start)
• Hydraulic feed units
• Rotary Index tables, and strip feed units
• Practical exercise and typical industrial circuits

Module 4

• Hydraulic equipment maintenance - why it’s so important
• Maintaining fluid cleanliness
• Maintaining fluid temperature and viscosity within optimum limits
• Maintaining hydraulic system settings to manufacturers’ specifications
• Scheduling component change-outs before they fail
• Following the correct commissioning prodedures
• Conducting failure analysis
• The true cost of hydraulic fluid leaks
• Fluid contamination and dealing with water in hydraulic fluid
• Troubleshooting basics and how to avoid costly mistakes
• Symptoms of common hydraulic problems and their causes
• Locating internal leakage
• Fundamentals of hydraulic component and cylinder repair

Module 5

• Electrical and pneumatic symbols and standards
• Interaction of control section and pneumatic power section
• Components of power section control section
• Electronic sensors (inductive, capacitive and infrared)
• Systematic production and reading of electrical circuit diagrams
• Operating modes of electro - pneumatic control systems
• Coordinated sequence controls
• Fault finding procedures and systematic troubleshooting
• Safety regulations and valid standards for pneumatics
• Practical exercises for all circuits