air cylinder

Types of air cylinders

An air cylinder, also known as a pneumatic cylinder, comes in several configurations to serve different applications best. The most common models are listed below:

• Air cylinders with end lock

  The locking mechanism locks the piston position at both ends. An unlocked piston can move freely in either direction to perform tasks. A locked piston remains in one position, allowing the locked workpiece or item to hold, clamp, or retain its position. Air cylinders with end locks usually have locking mechanisms at both ends of the cylinder. They are commonly used in the automotive industry, robotics, automation, and material handling.

• Rotary air cylinders

  Rotary cylinders convert linear motion resulting from the push-and-pull action of compressed gas into rotary motion. Sometimes they are called rotary actuators. They typically turn an object by a specified angle. Besides the automotive assembly line, workstations, or factories, where one may want parts of a device or instrument to turn by certain angles, the rotary air cylinder is essential in closing a valve or any function in which there is a need for precise angular rotation.

• Double-acting air cylinders

  A double-acting air cylinder has two ports for pushing and pulling the piston to perform its function quickly. The compressed air that fills the first port moves the piston to the other position. Once push action completes, compressed air fills the second port to push the piston back. Pneumatic springs and push rods are two examples of double-acting air cylinders.

• Single-acting air cylinders

  A single-acting air cylinder has just one entry point for the compressed air to push the piston out. The piston returns to its original position by the force of gravity or a spring action. Single-acting air cylinders are used in clamping, lifting, or pressing where the piston needs to return to its original position. In such a case where pushing action is only required in one direction, cooling fans for laptops or computers use single-acting air cylinders to push hot air out through the vents.

• Tandem pneumatic cylinders

  Two single-acting or double-acting air cylinders placed one after the other make a tandem pneumatic cylinder. The motion of such air cylinders is additive, making them ideal for applications that require a long stroke or a high thrust force. In vehicles, tandem cylinders in the braking system ensure the vehicle comes to a complete stop. Material handling, press machines, and packaging also benefit from using tandem pneumatic cylinders to increase a machine's thrust force or stroke length.

Specification and maintenance of air cylinders

• Specification

  A typical specification for an air cylinder includes the model with variants, working media and temperature range, pressure capacity, cylinder bore diameter and stroke length, connector types, mounting type, and other features.

• Maintenance

  The correct installation is the first step in keeping an air cylinder functional. Ensure that the air supply system is free of contaminants because they could damage internal seals and components. Accurately align the cylinder and avoid over-tightening the connectors. A well-chosen mounting bracket or clamp will keep the cylinder in place during operation.

  Set the limits of the pneumatics cylinder's stroke to avoid uncushioned or overstretched scenarios that can cause damaging impacts. Stretched and impacted situations can lead to deformed piston rods and damaged cylinder heads or seals. Regular inspections can help detect misalignments and impact damages early on.

  Maintenance consists of regular inspections for damage to external parts such as seals, hoses, and connectors. Look for air leaks around the hose and connector joins and between the cylinder body and the seal.

  Clean the air cylinder and avoid products that can harm anodized or coated surfaces. Use cotton swabs for hard-to-reach areas. Protect the piston rods from scratches and corrosion by retracting them into the cylinder during prolonged inactivity. Keeping them retracted will also prevent dirt ingress.

Scenarios of air cylinders

Air cylinders are primarily used in industrial settings to provide linear motion and power. This is commonly seen in large factories and assembly plants where machines are responsible for lifting objects, high volumes of product are packaged, and details such as precisely cut and fitted wood pieces are sought after.

However, the manufacturing industry is not the only place that air cylinders can be found. They are also commonly found in the following:

• Automotive industry & factories

Air cylinders are critical components in the automotive industry. They are commonly used for car assembly lines where products and parts need to be moved. Generally, they are used for lifting, pressing, punching, shearing, stacking, and other actions.

At least one or more air cylinders can be found in every car. They are used in the car's suspension system to absorb shock and keep the tires on the road. Specifically, a heavy-duty air cylinder is used. These can be found in the strut or shock absorber.

• Construction industry

Heavy-duty air cylinders are commonly used in the construction industry due to their high level of strength and ability to lift heavy objects with ease. Generally, they are found in lifting applications such as scaffolding, lifts, and pallets. However, they can also be found in places such as crimping and marking machines.

• Packaging and warehousing

Packaging systems and conveyor belts are where air cylinders can mostly be found. Whether it is the conveying part, the automated packaging machines, or the handling, sorting, and picking parts, air cylinders play a crucial role in ensuring packages are well taken care of and delivered to their final destinations without hassle and delay.

Some specialized air cylinders are more suitable for certain applications in packaging. For example, a T-slot air cylinder with a guide may be a better choice when dealing with guiding and aligning duties.

In warehousing, air cylinders automate the process of sorting, picking, and palletizing goods. Products are moved with precision and ease, stacking goods, especially heavy goods that are too cumbersome for humans to carry, with ease. Here again, an air cylinder with guide rails may be better suited for the job as it can handle more weight and deal with more demanding situations.

As evident, air cylinders are used in multiple applications and industries. Their simple design and efficient operation make them a staple in countless mechanical systems.

How to choose air cylinders

The following tips will help users choose the right pneumatic air cylinder for their application among the many options available.

• Focus on load and thrust requirement

  Users should start by determining their thrust requirements. They should consider the weight of the load the cylinder has to move and calculate the thrust required to accelerate it. After this, they can select a cylinder with a bore size that provides the necessary thrust.

• Consider the stroke length and size

  The load's position determines the stroke length users will need. They should measure the distance that needs to be traversed and account for the mounting considerations and any cylinder movement. If in doubt, users should consult with an expert. Also, users should ensure the cylinder's size will fit within their equipment's design.

• Examine the mounting style

  If the cylinder will be mounted onto a flat surface, the user may need to choose a cylinder with a mounting bracket or a built-in tie rod. If the cylinder needs to be fixed within a confined space, the user may consider the square or integration-mount style. The mounting options should provide a secure fit that allows the cylinder to function properly.

• Check the environmental considerations

  Users should choose a cylinder that can withstand the temperature ranges and potential exposure to contaminants or corrosive substances in their setting. If the work environment has the risk of ignition, users may need to select cylinders with anti-ignition standards that meet the applicable requirements.

FAQ

Q1: How to choose the right air cylinder for a specific application?

A1: Consider factors such as the required force and load, working pressure and vacuum levels, operating temperature, available power sources, desired size and weight constraints, noise sensitivity, and safety regulations of the application. Once the above factors are analyzed, it will be easy to select the right air cylinder.

Q2: Can custom air cylinders be manufactured?

A2: Yes, some manufacturers can modulate the air cylinder according to the specific requirements, such as size, shape, and pressure rating.

Q3: What are some trends in air cylinder technology?

A3: The trend of air cylinder technology is developing toward intelligent and integrated functions. With the development of sensor technology and electronic technology, the air cylinder can realize automatic control and feedback function. In addition, the integration of air cylinders and actuators and other functional modules is also a trend, which can reduce system complexity and installation space.