When working with air bellows, correct installation is crucial for long-term durability and reliable performance in demanding environments. At Tevema, we emphasize process precision and the use of quality materials. Depending on the diameter size—ranging from 80 mm to 950 mm—and convolution type, installation can impact vibration isolation, stroke length, and natural frequency. Some bellows operate up to 12 bar if using four-ply construction, while standard models handle up to 8 bar. These specifications require careful handling. The type of closure—dismountable, bead ring, or crimped—determines how the bellow integrates into the machinery. Misaligned installations can result in premature fatigue, leaks, or height instability. This guide outlines how to select the right configuration, prepare the mounting interface, perform the connection, and verify post-installation performance. Following these steps will reduce failures, limit downtime, and extend system lifespan. Mastering the setup process is essential for achieving consistent isolation or actuation results.
Focus Keyphrase: Installing air bellows
Assessing the installation environment
Start by examining the environmental conditions before installing air bellows. Improper conditions reduce performance and shorten product life. Rubber components are sensitive to UV light, ozone exposure, and extreme temperatures. The ideal storage condition falls within ISO 2230 guidelines: cool, dark, dry, and free from ozone sources. For working media such as compressed air, nitrogen, or water, use bellows with stainless steel AISI-304 or AISI-316L parts to prevent corrosion. The temperature tolerance varies by compound: EPDM handles up to 115°C, while NBR endures oil exposure and up to 110°C. Confirm that the operating environment matches the specifications of the elastomer used. Remove abrasive debris or chemicals from the installation area to avoid rubber wear. Failure to control environmental variables may lead to cracking, bulging, or bonding failure. Proper environmental preparation ensures a long-lasting, vibration-resistant installation that operates within safe mechanical boundaries under various load and pressure conditions.
Choosing the correct bellow configuration
Choosing the right air bellow configuration is essential for performance, isolation behavior, and structural safety. Begin by identifying the correct convolution type: single, double, or triple. A single convolution model typically supports lower stroke lengths, whereas triple convolution designs allow extended motion and enhanced flexibility. Consider the maximum stroke—ranging from 20 mm to over 400 mm—and natural frequency, which varies between 1.2 Hz and 4.6 Hz depending on bellow size and inflation. Assess force requirements as well: some designs deliver up to 450 kN axial force at 7 bar. Match the design to operational needs, factoring in vibration absorption, stroke movement, and mounting constraints. Choose between dismountable, bead ring, or crimped styles depending on whether maintenance or fixed use is required. Crimped designs are compact and sealed. Bead ring types allow bolt mounting, while dismountable options offer full plate removal. Choosing the right setup avoids performance losses, misalignment, and excessive stress concentrations.
Mounting preparation and alignment
Proper mounting preparation ensures reliable performance and avoids issues like lateral loading or seal failure. First, confirm that mounting surfaces are flat, clean, and free of warping. Use a straight edge or caliper to verify surface tolerances within 0.1 mm flatness. The presence of uneven support can lead to radial stress on the vulcanized layers, resulting in premature damage. All threaded holes must align precisely with the bead plate or ring bolt pattern, typically ranging from M6 to M10 with G1/4″ or G3/4″ air inlets. If using soft base materials like aluminum, insert threaded steel bushings to prevent thread stripping. Ensure that air lines route with sufficient slack to accommodate the stroke motion. Avoid rigid plumbing that could restrict movement or transfer vibrations. Apply torque control during bolting to ensure even pressure distribution. Finalize preparation by dry-fitting all components before permanent installation. This step eliminates misfit surprises and ensures axial alignment under operating conditions.
Installing the end closures
Securely attaching the end closures is a critical part of installing air bellows. Begin by identifying the correct closure type: dismountable plates, threaded bead rings, or crimped assemblies. Dismountable types require installing two clamping rings between top and bottom plates. Apply uniform torque, typically 15 to 25 Nm, to each bolt in a crisscross pattern. This maintains even pressure and prevents air leakage at the bead. For bead ring types, verify that threaded, countersunk, or socket-head bolts seat properly into the mounting interface. These types use M8 to M10 bolts, often arranged in 6 to 12 holes depending on size. With crimped designs, verify correct bellow orientation before tightening since post-adjustment is not possible. Confirm that the air inlet port aligns with your pneumatic system. Use thread sealants rated for the intended pressure range. Ensure the rubber layers are not pinched between flanges or plates. Correct closure installation prevents failure, leaks, and structural deformation.
Air pressure connection and testing
The next stage in installing air bellows involves connecting the compressed air system and performing operational checks. Use fittings that match the air inlet specification, typically BSP or NPT threads in G1/4″, G3/8″, or G3/4″. Avoid over-torqueing the fitting to prevent cracking the embedded nut or damaging the rubber membrane. Begin pressurizing slowly while monitoring for smooth, even expansion. At 7 bar, most bellows generate forces between 2.4 kN and 450 kN, depending on design. Once inflated, check for leaks by applying a soap-water solution around seals and connectors. Bubbles indicate leakage. Cycle the system five to ten times to verify stroke behavior and identify any drift, misalignment, or unusual noise. If using multiple bellows, compare inflation symmetry. Inconsistent pressure distribution can suggest an undersized line or incorrect valve timing. Once stable, record baseline operating height and natural frequency, which can range from 1.2 Hz to 4.6 Hz. This process ensures safe and efficient operation.
Adjusting operating height and alignment
After pressurization, the operating height of the bellow must be precisely set to match the system’s design expectations. The design height—often between 60 mm and 375 mm—ensures the bellow operates at its most efficient position within its stroke range. Use a pressure regulator and, if necessary, a height sensor to maintain this target under variable loads. Misalignment between the top and bottom plates can generate lateral forces, shortening service life. Tolerances must remain within ±2 mm from true vertical to avoid these issues. For systems involving tilt or angular movement, select models with built-in angular compliance—up to 25° on some sizes. If lateral misalignment occurs, the flexible nature of the rubber allows absorption up to 30 mm, depending on diameter. Always verify system equilibrium under operating conditions, not just during static tests. Proper adjustment stabilizes performance, increases durability, and ensures uniform force distribution during continuous cycles or dynamic loading.
Performing final inspection and documentation
Once installation and inflation are complete, a detailed inspection and documentation process validates the setup. Begin with a visual inspection, checking for signs of twisting, buckling, or excessive bulging. Confirm that the installed operating height matches the specified design height within ±3 mm. Inspect all mounting bolts to ensure proper torque. Verify that the air inlet fittings are sealed, and recheck with a soap solution if needed. Use digital pressure gauges to log the air pressure used during initial testing. For reference, most bellows operate between 4 to 8 bar, with high-strength four-ply models reaching 12 bar. Document the natural frequency, measured with vibration sensors if applicable. Record serial numbers, model configurations, elastomer types, and installation date. Attach this report to internal maintenance logs. Schedule a checkup after the first 100 hours of use to detect any shifting or loosening. Documenting these elements ensures traceability, repeatability, and long-term reliability in industrial systems.
Ensuring long-term performance
Ensuring long-term bellow performance depends on regular inspection, pressure stability, and proper environmental shielding. Although most Tevema bellows are low-maintenance, they should still be monitored during periodic system checks. Inspect the rubber surface for surface cracks, swelling, or deformation, especially near high-tension areas. Check that the operating pressure remains within safe limits—never exceeding 8 bar unless the bellow is rated for 12 bar operation. Examine the surrounding environment for exposure to solvents, acids, or ozone, which can degrade even high-grade CIIR, EPDM, or NBR rubber. Install protective covers in dusty or abrasive environments. When isolating vibrations from large machinery, verify that the bellow continues to operate within the desired natural frequency window, typically 1.5 Hz to 3.5 Hz for most industrial cases. Log system behavior during peak loads. Replace bellows that show asymmetric inflation or pressure leakage. A proactive approach to monitoring ensures extended life, consistent performance, and reduced total system downtime.