Pneumatic Systems, End-of-Arm Tooling, and Line Troubleshooting

This advanced technical course equips technicians with the competencies required to service, calibrate, and troubleshoot compressed air networks, pneumatic actuators, and robotic end-of-arm tooling (EOAT) in automated packaging and sortation facilities. Learners analyze pneumatic schematics, sizing principles, flow control valves, directional valves, and vacuum generation equipment critical to case packers, pick-and-place robots, and palletizers. Emphasis is placed on the mechanical, electrical, and sensor interfaces that govern tooling operation, including gripper selection, vacuum cup maintenance, and collision detection mechanisms. Through extensive diagnostic methodologies, students learn to isolate intermittent failures, optimize line cycle times, and resolve throughput bottlenecks across complex material handling interfaces. Technicians will employ systematic root-cause analysis, digital multi-meters, pressure gauges, and diagnostic flowcharts to resolve simulated hardware and communication faults. The course culminates in an integrated capstone project addressing multi-subsystem breakdowns in a high-speed packaging environment.

InstructorJacob Calhoun

Prerequisites

PKG 105 PKG 110

Course outline

Lectures, virtual labs, and graded assignments — completed in your browser.

01Lesson 1: Compressed Air Conditioning, Regulators, and Distribution Systemslecture

02Lesson 2: Directional Control Valves, Actuators, and Fluid Power Schematicslecture

03Lesson 3: Flow Control Valves, Cylinder Deceleration, and Pneumatic Sizinglecture

04Hands-on Lab: Hands-On Lab: Pneumatic Circuit Assembly, Pressure Regulation, and Leak Detectionlab

05Lesson 5: Vacuum Generation, Venturi Ejectors, and Suction Cup Dynamicslecture

06Lesson 6: Mechanical Grippers, Rotary Actuators, and Compliant Tooling Mechanismslecture

07Lesson 7: End-of-Arm Tooling Utility Routing, Quick-Changers, and Safety Interlockslecture

08Hands-on Lab: Hands-On Lab: End-of-Arm Tooling Setup, Payload Adjustment, and Sensor Calibrationlab

09Lesson 9: Systematic Troubleshooting Methodology and Fault-Tree Analysislecture

10Lesson 10: Electrical Sensor and Limit Switch Diagnostic Techniques on Live Lineslecture

11Hands-on Lab: Hands-On Lab: Multifault Insertion and Rapid Electropneumatic Diagnosislab

12Lesson 12: Packaging Line Integration, Bottleneck Identification, and Cycle Timinglecture

13Lesson 13: Preventive Maintenance Protocols, Air Quality Audits, and Wear Analysislecture

14Capstone Service Project: Comprehensive Line Breakdown Diagnostic and Restorationassignment

Syllabus

["Week 1: Lesson 1: Compressed Air Conditioning, Regulators, and Distribution Systems", "Week 2: Lesson 2: Directional Control Valves, Actuators, and Fluid Power Schematics", "Week 3: Lesson 3: Flow Control Valves, Cylinder Deceleration, and Pneumatic Sizing", "Week 4: Hands-on Lab: Hands-On Lab: Pneumatic Circuit Assembly, Pressure Regulation, and Leak Detection", "Week 5: Lesson 5: Vacuum Generation, Venturi Ejectors, and Suction Cup Dynamics", "Week 6: Lesson 6: Mechanical Grippers, Rotary Actuators, and Compliant Tooling Mechanisms", "Week 7: Lesson 7: End-of-Arm Tooling Utility Routing, Quick-Changers, and Safety Interlocks", "Week 8: Hands-on Lab: Hands-On Lab: End-of-Arm Tooling Setup, Payload Adjustment, and Sensor Calibration", "Week 9: Lesson 9: Systematic Troubleshooting Methodology and Fault-Tree Analysis", "Week 10: Lesson 10: Electrical Sensor and Limit Switch Diagnostic Techniques on Live Lines", "Week 11: Hands-on Lab: Hands-On Lab: Multifault Insertion and Rapid Electropneumatic Diagnosis", "Week 12: Lesson 12: Packaging Line Integration, Bottleneck Identification, and Cycle Timing", "Week 13: Lesson 13: Preventive Maintenance Protocols, Air Quality Audits, and Wear Analysis", "Week 14: Capstone Service Project: Comprehensive Line Breakdown Diagnostic and Restoration"]