Pneumatic System Exhaust Operation Guide: Key Technologies to Ensure Efficiency and Reliability

In the field of industrial automation, pneumatic systems have become the core power source of automation equipment due to their high efficiency, cleanliness and easy maintenance. However, if the residual air inside the system (especially impurities and moisture in compressed air) is not discharged in time, it may lead to reduced equipment performance, shortened component life and even safety accidents. This article will deeply explore the correct method of pneumatic system exhaust and its importance to production operation, and analyze the technical development trend of the industry.

1.Hazards of residual air in pneumatic systems

①Efficiency loss

Residual air will form air resistance, hindering the normal flow of compressed gas, causing slow cylinder movement and delayed actuator response, directly affecting equipment beat and production efficiency. For example, in high-speed stamping equipment, a delay of 0.1 seconds may result in hundreds of movement errors per hour.

②Component corrosion and wear:

After the moisture in the compressed air mixes with the oil mist, it is easy to form an emulsion on the inner wall of the pipeline, corroding metal components (such as the inner wall of the cylinder and valve seals). At the same time, foreign particles will accelerate the wear of precision parts. Statistics show that the failure rate of systems without standardized exhaust can increase by more than 30%.

③Decreased control accuracy

Residual gas will produce a "hammer effect" when the pressure fluctuates, causing distortion of the pressure sensor signal, which in turn affects the stability of closed-loop control. This is particularly critical for manipulators or high-precision assembly equipment that require precise positioning.

④Safety hazards

The sudden release of high-pressure gas may cause pipeline rupture or component shedding, especially in high temperature or vibration environment, the unexhausted gas may become a potential source of danger.

2.Standardize the exhaust operation process

①Preparation

Tool selection: Use a dedicated exhaust valve (such as a quick exhaust valve or a drain valve with a filter function) to avoid secondary contamination caused by improper opening control of an ordinary ball valve.

System pressure relief: After shutting off the gas source, confirm that the system pressure returns to zero using the pressure gauge, and operate the actuator (such as a cylinder) back and forth several times to release residual energy.

②Staged exhaust

Exhaust of the main pipeline: Starting from the outlet of the gas tank, open the low-level exhaust valve of each branch pipeline in turn and use gravity to discharge the liquid water.

Terminal equipment exhaust: For components such as cylinders and solenoid valves, the "pulse exhaust method" is used - quickly switch the control valve 3 to 5 times, and use air flow impact to remove impurities in dead corners.

③Dynamic testing and verification

After restarting the system, monitor whether the pressure curve is stable (it is recommended to use a digital pressure sensor to record in real time), and observe the consistency of the actuator's action.

For precision systems, the gas flow rate after exhaust can be detected by a flow meter to ensure that the designed value is reached.

④Residue detection technology

Use a dew point meter to detect the humidity in the pipeline to ensure that it is lower than Class 4 of the ISO 8573-1 standard (dew point below -20°C).

Infrared thermal imagers can assist in identifying local condensation points and optimizing the exhaust valve installation position.

⑤Regular maintenance system

Develop a preventive maintenance plan (such as daily draining, quarterly pipe flushing) and record the frequency of exhaust and failure correlation data.

Adopt filter pressure reducing valve with automatic drainage function to reduce labor maintenance costs.

3.Industry technology development trends

①Intelligent exhaust device

The new generation of exhaust valves integrates pressure sensors and IoT modules, which can monitor the system status in real time through PLC and automatically trigger the drainage program when impurity accumulation is detected. For example, the AI algorithms built into some valve bodies can dynamically adjust the exhaust frequency according to the ambient temperature and humidity.

②The combination of modular design

Quick-plug exhaust unit and standardized interface shortens maintenance time by more than 50%. It also supports online replacement of parts to avoid system downtime.

③Environmentally friendly materials application

The cylinder inner wall and fluororubber seals using nano coating technology can significantly reduce the moisture adhesion rate and extend the life of components.

④Predictive maintenance supports

The analysis of historical exhaust data through the cloud platform, which can predict the deterioration trend of components and provide early warning. For example, a certain brand of pneumatic management system can determine the risk of pipeline blockage through the pressure fluctuation spectrum.

4.Conclusion

Standardized exhaust is not only the basic operation of pneumatic system maintenance, but also the core link to ensure production efficiency and reduce operation and maintenance costs. With the breakthrough of intelligent and new material technology, the self-maintenance capability of pneumatic components will continue to upgrade in the future, providing more reliable power support for industrial automation. Enterprises need to optimize operating procedures and technology selection simultaneously to maintain equipment efficiency advantages in the fierce market competition.