Equipment set TP 501+ – Advanced level systematic troubleshooting

Equipment set TP 501+ – Advanced level systematic troubleshooting

Equipment set TP 501+ from Festo Didactic is an extension to equipment set TP 501. TP 501+ contains components with specified, realistic defects. It enables hydraulic circuits to be constructed with the TP 501 and individual components to be replaced by defective ones.

Using our experience in industrial environments, we were able to define typical error patterns for hydraulic systems and adopt these for the components contained in equipment set TP 501+.

Systematic troubleshooting and professional error elimination are an essential part of everyday operating life in many jobs in the fields of mechanics, mechatronics and electrical engineering. In order to acquire a skills in this area via a structured procedure that takes into account safety aspects, it is important that systematic troubleshooting is both learned and practiced. Key to this are:

  • Understanding circuits and discerning any non-conformities
  • Delimiting/precluding any error areas
  • Locating and rectifying errors

This procedure assumes specialist knowledge such as modes of operation of individual components and their system limits.

Pressure relief valve with broken spring
One example of a defective component is a pressure relief valve with a broken spring. This defect may be due to a continuous load or a material flaw. The defect results in the spring length being shortened and hence in a reduction in the maximum pressure that can be set. The conspicuous symptoms result in a lower cylinder force. Pressure sensors or force sensors may not switch, which can lead to interruptions to operation cycles or process safety being put at risk.

Flow control valve with damaged pressure compensator
Another example of a defect is a two-way flow control valve with a damaged pressure compensator. While intact, the valve ensures a constant volumetric flow rate, regardless of the load pressure. The pressure compensator is not working in this case however. The differential pressure is no longer being regulated via the throttle valve. Here, the flow control valve behaves like an unregulated throttle valve. A fault like this occurs if dirt has entered the system and the pressure compensator's piston has seized up in open position as a result.

Building on from Basic Level Hydraulics, the Advanced Level contains eight components appropriate for equipment set TP 501. Possible troubleshooting tasks are aimed at all job areas involving maintenance and repair activities. Special measuring equipment is not assumed since all symptoms can be observed and are therefore visible. Error patterns can also be quantified using measuring equipment such as a flowmeter or pressure gauge however.

Study materials
A description is included for each defective component describing both its function and the fault. A flow chart, which guides learners systematically from observation of the symptom to the repair task, is also included.

Supplementary media

  • Design and simulation using FluidSIM
  • Diagnostic system TP 810 with FluidLab-M
  • Textbook: Basic principles of hydraulics and electrohydraulics
  • eLearning course: hydraulics
  • eLearning course: electro-hydraulics
  • Hydraulics poster set


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