The ways machines experience downtime related to poor air quality

Air quality insights

• Poor air quality in a manufacturing facility can have a negative impact on computer numerical control (CNC) machines and robots.
• Improving air quality in a manufacturing environment can improve machine and equipment longevity.

Poor air quality in manufacturing environments can significantly impact the performance and longevity of machines, leading to unexpected downtime and increased operational costs. While the health of employees is often prioritized when discussing air quality, the negative effects on machinery are equally concerning, particularly in high-precision environments like machine shops and computer numerical control (CNC) operations.

With the growing presence of robots and automation in the manufacturing industry, maintaining clean air has become even more critical, as these advanced systems are highly sensitive to environmental conditions. By understanding the sources of poor air quality and implementing best practices, manufacturers can protect their machinery, enhance productivity and ensure seamless operations.

The role of air quality in machine downtime

Airborne contaminants such as dust, oil mist and chemical fumes are common in industrial environments. These pollutants can settle on sensitive machine components, clog cooling systems and infiltrate electrical circuits.

For high-precision machines like CNC equipment and now increasingly for industrial robots, even the smallest particle of dust can interfere with the accuracy of operations and lead to frequent breakdowns. With robots performing critical tasks like material handling, assembly and welding, keeping these machines free of contaminants is essential for smooth operations. Poor air quality in an automated environment not only impacts the machinery itself but can also disrupt the programming and precision of robotic systems, leading to inefficiency and downtime (see Figure 1).

Figure 1: An example of poor air quality from computer numerical control (CNC) machining operations. Courtesy: Bee Clean Specialties

1. Dust and particulate contamination

CNC machines and robots in manufacturing are designed to work with extreme precision. However, contaminants in the air, such as dust, can settle on critical parts like bearings, rails, lead screws or robotic joints. These particles disrupt smooth movements, causing friction and wear over time, which reduces the accuracy of both CNC machines and industrial robots. As more manufacturers integrate robots into their production lines, ensuring the environment is free from dust and particulate matter becomes even more important.

For example, when dust accumulates in the linear motion systems of CNC machines or the joints and moving parts of robots, it creates resistance, making the machine or robot work harder to achieve the same level of precision. This not only increases wear on components but can also slow down production. In an automated environment, this loss of efficiency can be especially costly, as multiple machines and robots are interconnected in a single production workflow. Without proper air filtration and cleaning systems, the shop floor becomes a breeding ground for inefficiency across the entire production line.

2. Cooling and lubrication system failures

CNC machines and robots rely heavily on cooling and lubrication systems to maintain optimal performance. Airborne contaminants can obstruct these systems by clogging cooling fins and filters, leading to overheating and increased wear on moving parts. Overheated machines and robots are not only less accurate but also prone to sudden breakdowns, requiring costly repairs and extended downtime.

Lubrication systems are equally vulnerable to contamination. If foreign particles enter the lubrication system of either CNC machines or robots, they increase the friction between moving components, accelerating wear. Over time, this leads to premature equipment failure, unexpected breakdowns and extended downtime, as machines and robots are taken offline for repairs.

In robotics, the precision of movement is critical and cooling systems ensure that robots maintain their calibration and effectiveness over long shifts. If these systems are compromised due to poor air quality, the entire production line can face slowdowns, forcing manufacturers to pause operations to clean and service the affected machines.

3. Impact on electrical components and wiring

Airborne particles don’t only affect mechanical components; they also impact electrical systems. Contaminants can settle on connectors, wiring and other electrical components, increasing the risk of short circuits and other malfunctions.

For robotic systems, this risk is especially heightened because robots rely on complex wiring and electrical systems to execute precise commands. Even a small buildup of dust or mist can interrupt signal transmission in robots or CNC machines, causing them to malfunction or shut down unexpectedly. In some cases, the presence of moisture or conductive particles can result in ground faults that trigger machine or robot shutdowns.

For industrial robots, electrical integrity is paramount for maintaining precise, repeatable movements. A malfunction in the wiring or electrical system can lead to positioning errors, faulty operations and, in worst-case scenarios, catastrophic machine failure, causing downtime across the entire production line.

4. Ground fault interrupter protected CNC machines and robots

Many CNC machines and robots are equipped with ground fault interrupter protection to prevent damage from electrical faults. If airborne particles clog the filtration system or enter the machine’s circuits, it can cause a ground fault that shuts the machine down entirely. These shutdowns are often unpredictable, leading to lost production time and the need for technical intervention to resolve the issue.

As robots become more integral to automated production lines, a ground fault in one machine can cause ripple effects across multiple systems, further underscoring the importance of maintaining clean air in these environments.

5. Thermal expansion and machine accuracy

Poor air quality can also impact the ambient temperature around machines and robots, leading to inaccuracies in machining and robotic operations due to thermal expansion. In machine shops and manufacturing environments where precision is critical, even slight variations in temperature can affect the dimensions of machined parts or disrupt the precise movements of robots. Air filtration systems help to regulate the temperature around both CNC machines and robots by maintaining constant airflow, reducing the risk of thermal expansion and ensuring consistent operational accuracy.

In environments where robots are used for tasks like welding, temperature control is even more critical, as thermal expansion could affect the robot’s ability to perform repetitive, precise welds. A poorly ventilated environment could result in defective products, which require rework, leading to further downtime and resource wastage.

How robots can help achieve higher air quality in manufacturing facilities

As manufacturing processes become increasingly automated, the importance of clean air in facilities with CNC machines and robots cannot be overstated. To minimize air quality-related downtime, manufacturers must prioritize air quality control through proper system design and regular maintenance. Facilities can implement a combination of air filtration, source capture systems and best practices for machine and robot care to ensure smooth, continuous operation.

There are several best practices to ensure automated manufacturing plants maintain safe air quality. These best practices include:

Implement effective source capture systems: Source capture systems are designed to filter and remove contaminants directly from the source before they can spread throughout the facility. This is especially important for machines and robots that generate fumes, dust or mist during operation. By installing these systems, manufacturers can significantly reduce the number of airborne particles that reach other machines or areas in the facility, protecting both human workers and automated systems from contamination.

Regular maintenance of air filtration systems: Air filtration systems need to be regularly inspected and maintained to ensure their effectiveness. Filters should be cleaned or replaced frequently and any issues with airflow or blockages should be addressed immediately. This helps to maintain a clean environment around machinery and robots, reducing the buildup of dust and contaminants on sensitive components.

Control environmental humidity and temperature: Humidity and temperature control are crucial in maintaining air quality in manufacturing environments. High humidity levels can cause dust and contaminants to become sticky and cling to machine and robot parts. On the other hand, temperature fluctuations can lead to condensation, which can short-circuit electrical components or cause rust on metal parts. Installing proper ventilation, air conditioning and dehumidification systems can prevent these issues.

Enforce cleanliness standards: Keeping the shop floor clean is vital in controlling airborne contaminants. Regular sweeping, vacuuming and wiping down surfaces help to minimize the amount of dust and particulate matter in the air. Additionally, implementing policies for personal protective equipment and proper cleaning protocols can further reduce the number of contaminants generated by personnel or equipment.

Use advanced monitoring systems: Monitoring air quality is essential for identifying potential risks before they become serious problems. Installing advanced air quality monitoring systems allows facilities to track levels of dust, oil mist, fumes and other contaminants in real time. These systems can alert maintenance teams to rising levels of pollutants, enabling them to take corrective action before machinery or robots are affected.

Why it’s critical to invest in air quality solutions

The cost of poor air quality in automated manufacturing environments is often hidden until it leads to downtime, expensive repairs or employee health issues. By investing in air quality improvement solutions, facilities can avoid these costly disruptions while ensuring better working conditions for their staff and prolonging the lifespan of their machinery and robotic systems.

Not only does better air quality reduce the frequency of machine and robot breakdowns, but it also improves overall productivity. Machines and robots that run smoothly and efficiently can produce higher-quality parts, minimize defects and operate at faster speeds. Furthermore, clean air is essential in reducing employee absenteeism and health-related issues, which can further disrupt production schedules.

Prioritizing air quality for a healthier work environment

Poor air quality is a critical but often overlooked factor in the downtime and inefficiency of high-precision machines and robots. Dust, particulate contamination and inadequate air filtration systems can lead to a range of mechanical and electrical failures, resulting in costly downtime and repairs. By prioritizing air quality through source capture systems, regular maintenance and advanced monitoring, manufacturers can enhance machine and robotic performance, reduce unexpected breakdowns and create a cleaner, healthier environment for their workforce.

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