Failure Modes and Effect Analysis of Electro-Pneumatics System

International Journal of Electrical and Electronics Research ISSN 2348-6988 (online)
Vol. 3, Issue 3, pp: (12-20), Month: July - September 2015, Available at: www.researchpublish.com
Failure Modes and Effect Analysis of

Electro-Pneumatics System
Priya Banerjee
B. Tech. Electrical and Electronics Engineering, Amity School Of Engineering and Technology, Amity University,
Noida, India
Abstract: This paper presents the FMEA (Failure Modes and Effect Analysis) as a methodology to analyze the
electro-pneumatics system. A minor failure may lead to severe impact on the performance of the equipment. The
Failure Mode and Effect analysis is a primarily a quality planning tool to identify failure and effect and prioritize
the risk on system, product or service. It is used to establish control, prioritize process and prevent process errors.
Thus, the various possible causes of failure and their effects of an electro-pneumatic system used in along with
ways of prevention are discussed in the work.
Keywords: FMEA, Risk Priority Number (RPN), Recommendations, Detection Number, Severity Number,
Occurrence.
I. INTRODUCTION
Failure Modes and Effect Analysis (FMEA) was first developed design methodology by the aerospace industry for safety
requirements. Failure Modes and Effect Analysis (FMEA) aims to identify the modes in which a product, service or
process can fail and hence estimate the risk associated with the specific failure causes. Knowing the failure causes we can
prioritize the actions to reduce risk of failure and make current control plan (process). Advantages of FMEA are:
Improve the quality, reliability and safety of a product
Increase customer satisfaction
Reduce system cost/maintenance cost

Collect information to reduce future failures
Reduce potential for concerns
II. FAILURE MODES AND EFFECT ANALYSIS

FMEA is quantitative, systematic method that helps to narrow down Key Process Input Variable (KPIVs) to a manageable
number for improvement or further analysis. It reduces cost by identifying system, products and process improvements
early in the development cycle.
A. When to use FMEA?
Designing a new system, product or processes.
When designs is implemented in new applications.

System, product or process has been defined but before starting a detailed final design.
When changing existing system, product or design.
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Research Publish Journals
B. Types of FMEA:
There are three types of FMEA.
Design FMEA: Analyses a new process, product or service design before rollout to understand how it could fail once
released. Exposes problems that may result in safety hazards, defects in product or service production processes.
Process FMEA: Used to improve existing transactional and operational processes to understand how people, materials,
equipment, methods and environment cause process problems.
System FMEA: Analyses systems and subsystems in the early stage of concepts and design.
C. Stages of FMEA:
TABLE I shows the three stages for Failure Modes and Effect Analysis
TABLE I: THREE PHASES OF FMEA
Phase Question Output

Identify What can go wrong? Failure cause and effect
What is the number failure has occurred and what Risk Priority Evaluation=
Analyse
are the consequences (severity*occurrence*detection)
Act What can be done to eliminate the failure Design solution, make plans, etc.
There are of two types namely: Design FMEA and Process FMEA. Design FMEA is to identify the known failure modes
and then ranking failures according to the relative impact on the product. The objective of Process FMEA is to improve
the existing process and find out how it can affect the system, environment and human. A product is considered to be
failed when it does not give desired result or when it malfunctions in some way. It is not necessary that failures can
happen only because of design or process failure but also can happen because of the operator error. FMEA is to eliminate
the root cause effect of any failure so as to improve the process and make ensure 100% customer satisfaction. Process
FMEA is an effort to prevent failures due to process before they happen so as to assess the risk associated with those
failure mode, to rank the issues in terms of severity, occurrence and detection and hence find the alternative measures to
prevent the failure.
Process FMEA consider five main elements of the process namely: People, Materials, Equipment, Methods and
Environment. Each of the failure modes has its own effects, causes and risks. Each potential failure mode of process or
product are rated on each of (Severity, Occurrence and Detection) ranging from 1 to 10, low to high. RPN is calculated by
using the formula (Severity*Occurrence*Detection). RPN is used to rank the urge for preventive actions to be taken for
each failure mode and effect.
D. Severity:
It is the parameter of the impact of the effect of the potential failure modes. In this we have to determine all failure modes
based on the functional requirements and their effects. Figure II shows rating scale for severity.
TABLE II: RATING SCALE FOR SEVERITY
Rating Meaning Example

10 Hazardous-without warning Death
9 Hazardous-with warning may endanger machine/operator
8 Very high loss of primary function
7 High reduction of primary function
6 Moderate loss of comfort function
5 Low reduction of comfort function
4 Very low lowered effectiveness
Non-returnable appearance observed
3 Minor
several times
2 Very minor Non-returnable appearance noticed once
1 None no effect
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E. Occurrence:
Occurrence is the chance that the one of cause or mechanism will occur. It is necessary to look at cause of failure and
number of times it occurred. A failed design is considered as a design weakness. Table III shows the rating scale of
occurrence.
TABLE III: RATING SCALE FOR OCCURENCE
Rating Meaning
10 Very high Failure is almost inevitable
9
High This process or similar process have often failed
8
7 This process has occasionally failed but not in major
Moderate
6 proportions
5
4 Low Isolated failures associated with similar processes
3
2 Very Low Failure likely to happen
1 Remote Failure unlikely
F. Detection:
Detection rank is determined by the prevention of failure modes from occurring. It is assessment of the probability that
the current process will detect s potential weakness or sub failure mode by failure mode of that part/component before it
effect the whole system. Table IV shows the rating scale for detection.
TABLE IV: RATING SCALE FOR DETECTION
Rating Meaning
10 No detection Controls cannot detect the existence of the failure
9 Very low Controls probably will not detect the existence of failure mode
8
Low Low chance to detect the fault
7
6
Moderate Controls may/may not detect the failure mode
5
4 Controls have a high probability of detecting failure mode, process
High
3 automatically
2
Very high Controls almost certain to detect the failure modes
1
G. Risk Priority Number (RPN):

It is a method to analyse the risk that could occur from potential failures modes identified whole doing Failure Mode and
Effect Analysis.
RPN= Severity*Occurrence*Detection
The RPN value for each potential system problem is used to compare issues within analysis, corrective actions may be
recommended or required to reduce the risk of occurrence of failure, increase the likelihood of prior detection so that it
could be rectifies at early stage and hence reduce severity of the failure effect
H. FMEA Procedure:
There are steps in order to determine a Process Failure Modes and effect Analysis. Fig.1 below shows the steps to find out
the Risk Priority Number.
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Fig: 1. STEPS FOR FAILURE MODES AND EFFECT ANALYSIS
III. CASE STUDY AND FMEA IMPLEMENTATION

Case study is conducted and FMEA technique is applied to the electro-pneumatic system. For the analysis, the system
breakdown details for the past three years are taken. The ranking of severity, occurrence and detection is selected on the
basis of the parameters been discussed.
A. Electro-pneumatic:
Pneumatic control system using electricity as actuating medium is termed as Electro-pneumatic control system. Nowadays
pneumatic devices use clean and dry air as an energy source for the system. The actuator then converts compressed air
into mechanical motion. The type of motion depend on design of actuators. Solenoid operated control valve uses two
energy forms- electricity and air.
B. Advantages:
Quick and sure action
Less maintenance
Minimum wastage of energy
Availability of air
Cleanliness
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C. Uses:
Door open/close operation
Material stacking
Embossing part
Refinery
D. Working of Electro-pneumatic system:
In Electro-pneumatic system the control of pneumatic cylinder are electrically actuated valves hence has advantage over
all other forms. The path of electricity is controlled using switches which is used to make or break electricity contact
which controls pneumatic valves. These system are hence termed as electrically or electromagnetically operated valves.
A solenoid is used in such pneumatic valves to act as the actuating elements. A pneumatic control system consists of a
pneumatic driving element and an electromechanical control part consist of a solenoid, push button switches, relays, limit
switches, etc. The energised coil attracts or repel the valve. When the switch is closed current flows through the coil and
the coil get energized it results the valve to move in such a way that it switch the valve and air flows through the cylinder
and cylinder piston and cylinder gets filled. When switch is open the solenoid get de-energised and hence the connections
breaks off. Electro-pneumatic system are basically classified into three parts: Energy, Control elements and Actuators.
E. Energy:
It consists of compressor, reservoir, and air dryer, etc.
Compressor: It is a machine that compresses air or other type of gas from a low inlet pressure to higher desired
pressure level. This is achieved by decreasing the volume of gas of positive displacement unit.
Reservoir: It is used to store the compressed air and act as a downstream to stabilises the compressed air
Air dryer: It is used to remove water from air, the condensate which are found in form of relative air humidity.
F. Control elements:
It consists of valves which are basically used for control flow, direction and pressure of air.
Direction Control Valve: Directional control valve is attach with solenoid so that it can move backward and forward. The
movement of the valve allow compressed air to go into the airway. Other type of valves includes: Non return Valve, flow
control valve, pressure control valve. There are different types of valves been used in Electro-pneumatic system which
are:
2/2 way directional valve: It is used to drive air motors and pneumatic tools
3/2 way directional valve normally closed type: It is used to drive single acting cylinder or act as on/off switch.
3/2 way directional valve normally open type: It is used to drive single acting cylinder
5/2 way directional valve: It is used to drive double acting cylinder with individual exhaust.
G. Actuators:
It consists of pneumatic cylinders, pneumatic motors, etc. Actuators are motor which are used to move and control a
system. It is operated by mechanically, pneumatically or electrically, etc.
H. Electronics components:
There are six basic electrical devices been used to control fluid power which are:
Push button Switches: These are used to make or break the electrical circuit for solenoid operated valves. They are
primarily used for starting and stopping of operation of machinery. Push button are of two types are momentarily push
button which return to their unactuated position when they are released and maintained contact push button- Maintained
push button has a latching mechanism to hold it in the required position.
Page | 16
Relays: They are of an electromagnet devices that control the position of contacts. The operated position is assumed
when the magnet is energised. The switches used are either normally closed (NC) or Normally Open (NO) type. In
normally closed type switch, the contacts gets broken when actuated whereas in NO it is the opposite of NC.
Limit Switches: Any switch that is actuated due fluid force component consisting of piston rod and a position of load
is termed as limit switch. The limit switch gives an electrical signal whereas limit switch are mechanically actuated.
Pressure Switches: Pressure switch are used to sense any change in pressure. Diaphragm is used to expand or contracts
in response to increase or decrease in pressure. When pressure is applied at the inlet the diaphragm expands and pushes
the spring loaded plunger to make/break contact.
Solenoid: Solenoid is electrically actuated directional control valves which forms a platform between the two ports of
electro-pneumatic control. They are switched with the help of solenoid. These are divided into two types namely spring
return valves which only remain in actuated position as long as current flows through the solenoid and double solenoid
valves which retain the last switched position even when no current flows through the solenoid.
Temperature switch: They are automatically sense a change in temperature and opens or closes the electrical switch
when a predetermined temperature is reached which can be operated either normally open or normally closed.
TABLE V: FMEA CHART
Components Potential Potential S Potential O D Action Action Risk

Failure Failure Causes C E Recommended taken Priorit
Mode Effects E C T y
Numbe
V r
Directional Failed to There is 8 Pressure 4 7 Replace dirty Replacement 224
Control Valve allow no outside filters, clogged
- Attach with compress movement parameter inlet line
solenoid so ed air to in the Incorrect 2 7 Check all the Repair the 112
that it can go into directiona assembly connections faulty part
move forward the l control during from the start
and backward airway of valve maintenan
thus allow the valve ce
compressed Water in 6 4 Check Filter, Repair the 192
air go into the the air Regulator, FRL unit
airway supply line Lubrication
Wear of 3 4 Replacement Replacement 96
part
No 2 3 Check there is Hose 48
signal/No no leakage in replaced
gas supply the system
Spring 3 6 Replacement Replacement 144
problem of the spring
Leakage 4 5 Replacement Replacement 160
Crack in 2 4 Replace or Repair 64

housing Repair
Non return Failed to There is 8 Pressure 4 7 1.Replace dirty Replacement 224
valves- It pass the malfuncti outside filters, clogged
allows air to air oning/no parameter inlet line
flow in one through movement 2.Tighten leaky
direction, but airway/bl of the connection
blocks it from ock the valve Diaphragm 1 7 Check there Replacement 56
flowing back air in failure should be no of the
in the opposite opposite crack in diaphragm
direction direction diaphragm
Mechanica 2 5 Check the Replacement 80
l failure- spring/ball of the spring
spring/ball minute detail
Page | 17
Incorrect 2 7 Check all the Repair the 112

assembly connections faulty part
or from the start
maintenan
ce
Water in 6 4 Check the Repair the 192
the FRL(Filter, FRL unit
compresse Regulator,
d air Lubrication)
supply line unit
Leakage 3 5 1.Check the Replacement 120
hose and pipe
2.Replace or
Repair
Crack in 4 4 Replace or Repair 128
housing Repair
Flow Control Unable There is 8 Pressure 4 7 1.Replace dirty Replacement 224
Valves-It to sense malfuncti outside filters, clogged
influence the the oning/no parameter inlet line
volume of the volume movement 2.Tighten leaky
flow of of of the connection
compressed compress valve Diaphragm 1 7 Check there Replacement 56
air in both the ed air to failure should be no of the
direction be send crack in the diaphragm
to the diaphragm
airway Mechanica 2 5 Check the Replacement 80
l failure spring/ball in of the spring
minute detail
Incorrect 2 7 Check all the Repair the 112
assembly connections faulty part
during from the start
maintenan
ce
Water in 6 4 Check Filter, Repair the 192
the air Regulator, FRL unit
supply line Lubrication
Wear in 3 4 Replacement Replacement 96
parts
Cracking 3 4 Replace or Replacement 96
of housing Repair
Pressure 5 6 Replace dirty Cleaning of 240
failure filters, clogged inlet line
inlet line
Pressure Failed to Insufficie 8 Diaphragm 1 8 Replacement Replaced 64
Regulators-It maintain nt/Excessi failure
reduces a high the range ve Leakage 4 5 1.Check the Replacement 160
input pressure of pressure hose and pipe
to a low pressure 2.Replace or
working required Repair
pressure and for the Intake/Exh 6 6 1.Replace dirty Leaky inlet 288
provides a operation aust port filters, clogged connections
steady output, failure inlet line tightened
despite 2.Tighten leaky
changes in the connection
Page | 18
input pressure Pressure 4 6 Replacement Replaced 192

switch not
working
Cable 3 6 Mechanical Cable 144
connector failure- broken connector
or damaged repaired
connector
Electrical 2 3 Check the Electrical 48
power electrical panel connections
failure for proper are corrected
connections
Tubing- It is Compres Insufficie 6 Bending 6 7 Replacement Replacement 252
used to sed air is nt/Excessi Clogging 5 5 1.Clean clogged Cleaning of 150
transport the unable to ve (Blocking) inlet line inlet line
compressed reach its pressure 2.Change
air to the desired system fluid
desired destinati Leakage 4 5 Tubing material Replacement 120
destination on ruptured
Fault in 3 7 Replace or Replacement 126
connection repair
Filters- It Contami Icing or 5 Water in 3 5 Check Replacement 75
removes nation freezing the FRL(Filter,
moisture and problem of the compresse Regulator and
debris is exhaust d air Lubrication
encounte air, supply unit)
red causing
the pump
Lockout 2 8 Mechanical Replacement 80
to cycle
valve failure-handle
erratically
failure jammed
Clogging 6 3 Clean the pores Replacement 90
Lubricators- It Insufficie Difficulty 5 Clogging/ 4 4 1.Clean clogged System fluid 80
injection oil nt oil in in Blocking inlet line changed
mist to help the operation
lubricate the system of moving Duct 2 3 Cleaning Replacement 30
moving parts parts blocked of ducts
of the system Contamina 3 3 Cleaning Cleaning 45
tion
Silencers-It Sound Loud 4 Mechanica 2 2 Replacement Replacement 16
eliminates the come sound is l failure-
noise coming from the heard ruptured
from the system from the part
system system
Reservoirs - It Failed to Insufficie 7 Cracking 3 6 Replace or Replacement 126
stores the store the nt/Excessi of housing Repair
compressed compress ve External 4 7 Tighten leaky Leaky inlet 196
air. ed air pressure leak in the inlet connection connections
system tightened
Electric Failed to The 8 Electrical 3 4 Check the Connections 96
controllers- it receive operation power electrical panel corrected
used to or send of control failure for proper
monitor a feedback valve is connections
process for the incomplet Proximity 4 5 Component Sensor 160
condition in a closing e sensor failure inside Replaced
machine and and failure proximity senor
according give opening PLC 2 3 Check the Snubber 48
feedback of switch failure wiring of PLC circuit can be
used
Page | 19
IV. ANALYSIS
Detailed component analysis has been done to reduce its failure rates. Proper care should be taken while scheduling
maintenance. This process has considered RPN because of its higher degree of severity, occurrence and detection. Proper
maintenance and training to engineers can reduce RPN value. Higher RPN has been observed in case of leakage, worn out
parts, etc. To reduce RPN these factors must be taken into consideration.
V. CONCLUSION
The work shows the FMEA study of electro-pneumatics system. The electro-pneumatics system is studied and failure
modes are identified. Keeping in mind failure effects of faults severity is rated and then based on causes, prevention and
number of occurrences, the detection value is rated. Failure modes and Effect Analysis helps to calculate RPN which
helps to reduce the possible causes for the failure of component or system.
REFERENCES
[1] SEIGISMUNDO A., MIGUEL, PAC. Failure mode and effects analysis (FMEA) in the context of risk management
in new product development. A case study in automotive industry. Industrial Journal of quality and Reliability
Management.
[2] Bradley N., 2010, Marketing Research: tools and techniques, 2 nd edition, New York, Press.
[3] Creveling C.M., Slutsky J.L. and Antis D., 2003, Design for Six Sigma, Pearson, New Jersey.
[4] Bradley, J.R. and Guerrero, H.H., 2011, An alternative FMEA method for Simple & Accurate rating of Failure
Modes, Decision Sciences, Vol 42 pp 743-771.
[5] Duckworth, H.A. and Moore, R.A., 2010, Social Responsibility: Failure Mode Effects and Analysis, CRC Press,
New York.
Page | 20

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What are the different types of FMEA?

What are the different types of FMEA?

What are the stages of FMEA?

What are the stages of FMEA?

International Journal of Electrical and Electronics Research ISSN 2348-6988 (online)

Failure Modes and Effect Analysis of

Improve the quality, reliability and safety of a product

Increase customer satisfaction

Reduce system cost/maintenance cost

II. FAILURE MODES AND EFFECT ANALYSIS

When designs is implemented in new applications.

Phase Question Output

Rating Meaning Example

G. Risk Priority Number (RPN):

Fig: 1. STEPS FOR FAILURE MODES AND EFFECT ANALYSIS

III. CASE STUDY AND FMEA IMPLEMENTATION

Minimum wastage of energy

Components Potential Potential S Potential O D Action Action Risk

Crack in 2 4 Replace or Repair 64

Incorrect 2 7 Check all the Repair the 112

input pressure Pressure 4 6 Replacement Replaced 192

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