A new belt conveyor overflows at the transfer point, or the belt whips and mistracks because it was sized by eye. The belt width looks generous, but the material rolls off the edges at the…
A bolted joint leaks, or the bolt breaks in service, even though the wrench clicked at the target torque. The torque was set, but the actual bolt tension was wrong. Torque is not preload. Tightening…
A hydraulic system runs hotter than the oil spec, the tank warms to 60 C, and the oil turns dark. The pump and valves are fine, but the system is dumping all its wasted heat…
A proximity sensor works on the bench but fails on the machine, or triggers on the wrong object. The sensor was chosen for its rated distance, but the actual target, mounting, and metal around it…
A flange joint leaks after the plant reaches operating temperature, or the gasket crushes on assembly. The flange looked flat and the bolts were tightened, but the seal did not hold. Gasket selection is not…
A vacuum gripper holds the part, but the robot cycle is slow because the suction cup takes too long to pull vacuum, or it leaks and drops the part under load. The vacuum generator was…
A roller chain drive runs smoothly at low speed but vibrates and rattles at high speed, or the chain jumps teeth under load. The sprockets and chain were matched by pitch, and the drive still…
An electric motor runs hot in a dusty cabinet. It was sized for the torque, and it works, but its insulation cracks after a year or two and the winding fails. Motor sizing is not…
A pneumatic cylinder moves too fast on extension and slams into its end cap, or creeps on retraction. The operator turns a flow control on the supply, and one direction improves while the other gets…
A directional control valve spools to its neutral position and the cylinder drifts, or the pump unloads and pressure collapses when it should hold. The valve symbol looked correct on the drawing but the circuit…
A casting comes out with internal cavities at its thickest sections, found only after machining or by X-ray. The mold filled correctly and the surface looked sound. The problem is shrinkage: metal contracts as it…
A stepper-driven indexer moves accurately at low speed and loses position during fast moves, ending a few steps short without any fault. Stepper motors are open loop: the controller commands steps and assumes they happen,…
A long belt conveyor keeps running to one side, rubbing the structure and fraying the edge. The belt is tracked, adjusted, and drifts back within hours. Mistracking is rarely a single fault. It follows from…
A pulley or coupling is fitted to a shaft with a parallel key. It works initially, then develops play, the keyway elongates, and the connection slips under load. The shaft and hub are strong enough….
A hydraulic circuit uses an accumulator to cover a peak flow or absorb shocks. The unit is installed and the peak still drops pressure, or it discharges almost no usable oil when needed. The accumulator…
