Multidisciplinary Fault Finding
Industrial faults rarely respect trade boundaries. A problem presenting as electrical may have a mechanical root cause. A PLC fault may originate in a hydraulic circuit. Effective fault finding requires the ability to analyse complete systems rather than isolated components — and the experience to know where to look.
Systems Covered
- Mechanical systems
- Electrical systems
- Hydraulic systems
- Pneumatic systems
- PLC and control systems
- Variable frequency drives
Diagnostic Approach
Faults are diagnosed by identifying the true root cause rather than passing responsibility between trades. Every investigation starts with a complete system understanding — not an assumption.
Support is available onsite or remotely via TeamViewer and remote camera systems where practical.
Diagnostic Techniques
A wide range of diagnostic tools and techniques are employed depending on the nature of the fault. This includes both software-based analysis and hardware instrumentation.
PLC-Based Diagnostics
- PLC fault logging and fault history analysis
- PLC state monitoring during machine operation
- Use of RS Trends and trending software for signal capture
- Monitoring analogue and digital I/O signals in real time
- Capturing intermittent faults through continuous logging
Signal & Power Analysis
- Oscilloscope usage for high-frequency signal analysis
- Voltage drop analysis across circuits and connections
- Harmonic investigation on power supplies and drive outputs
- Analogue signal integrity checking
- Encoder and resolver signal verification
CH1 (Yellow) — Supply Voltage | CH2 (Green) — Current | Thyristor switching disturbances visible on current trace
Case Study
Intermittent Earth Leakage Fault — Multiple Root Causes Identified
A customer site requested support to investigate an intermittent earth leakage fault. Investigation revealed faulty relays, thyristor switching disturbances causing false trips, an incorrectly configured voltage monitoring relay, and a related emergency lighting issue — all interconnected and all requiring methodical diagnosis to resolve.
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