A Proposed Method for Online Condition Monitoring of Pneumatic Systems Under Different Operating Conditions and Parameters for Optimal Energy Consumption

Pneumatics presents an alternative to electric and hydraulic actuators used in manufacturing industries. Pneumatic components provide a safe and reliable opportunity to automate a production line. However, pneumatic systems are notoriously expensive to operate as a result of system losses and inefficiencies. Typical systems have an output efficiency of 10%–12%. The Problems are — there is a fluctuating system pressure, which can cause air tools and other air-operated equipments to function less efficiently, affecting production; excess compressor capacity, resulting in higher than necessary costs due to no tracking of air consumption; decreased service life and increased maintenance of supply equipment due to unnecessary cycling and increased run time. This offers a significant improvement opportunity to meet targets concerning energy consumption. Leakages and excessive pressures are commonly identified as major sources of waste. Leaks or chokes in a compressed air system can be in various types due to diversified reasons. The proposed simulation method aims at the detection of faults based on signatures obtained. It has significance in terms of potential energy savings, decrease in breakdowns and increase in the service life of components. The Transfer function of a system is obtained by mathematical modelling of a system. The fault conditions are simulated in MATLAB SimulinkR to get results.