Selecting the appropriate air bellows for your specific business requirements can significantly impact operational efficiency, equipment longevity, and overall cost-effectiveness. We at Tevema understand that navigating through the various options available in the market can be challenging. With decades of manufacturing experience and technical expertise, we’re committed to helping you make informed decisions when it comes to choosing the right air bellows for your industrial applications.
Industrial air bellows are versatile components that serve dual purposes – as actuators generating force and movement, and as isolators absorbing unwanted vibrations. The key to maximizing their benefits lies in understanding your specific application requirements and matching them with the right product specifications. This comprehensive guide will walk you through the essential factors to consider when selecting air bellows for your business needs.
Understanding air bellows construction and types
Before diving into the selection process, it’s important to understand the basic construction of air bellows. These components consist of a corrugated flexible body made of high-quality rubber bellows with reinforcing fabric plies and steel beads, all joined through a vulcanized construction. The complete air spring system is formed by fitting metallic end closures to the bellow ends.
There are three primary design alternatives to consider:
- Dismountable design: A removable set assembled with two clamping bead rings and top plates and bottom plates, featuring an air inlet connection in the top plate and studs or threaded holes for fixation.
- Crimped design: A non-dismountable set assembled by mechanically crimping top and bottom bead plates, with blind nuts for fixation and an air inlet connection in the top plate.
- Bead ring design: A dismountable set assembled with socket head, threaded, or countersunk type bead rings. The air bellow is directly assembled to the machine, or plates are required.
Understanding these design differences is crucial when choosing the right air bellows as they directly impact installation, maintenance, and performance characteristics.
Assessing your application requirements
The first step in the selection process is to clearly define your application’s needs. Are you looking for an actuator to generate force and movement, or do you need an isolator to absorb vibrations? This fundamental question will guide your entire selection criteria.
For actuator applications
If you’re seeking pneumatic actuators, consider these key factors:
- Load capacity: Determine the force requirements of your application. Air bellows can handle loads ranging from 0.5 to 450 kN, depending on the model and pressure settings.
- Stroke length: Assess the required movement distance. Different models offer varying stroke length capabilities.
- Space constraints: Measure the available installation space. Air bellows offer compact installation heights, making them suitable for space-limited applications.
- Operating conditions: Consider the environmental factors such as temperature, exposure to chemicals, oils, or outdoor elements. This will influence the elastomer compounds selection.
The advantage of using air bellows as actuators includes being maintenance free due to the absence of sliding sealing elements, resulting in lower operational costs compared to conventional cylinders. They also offer lateral misalignment absorption up to 30 mm, reducing costs by eliminating the need for precision guides.
For isolator applications
When selecting air bellows for vibration isolation:
- Isolation degree: Our air spring systems can absorb more than 99% of unwanted vibrations, offering the best isolation properties in the market.
- Natural frequency: Air bellows maintain constant natural frequency values with changing loads, ensuring uniform isolation.
- Load requirements: Determine the weight that needs to be isolated. Our range can isolate loads up to 380 kN per bellow.
- Noise reduction: Consider if effective isolation from structurally transmitted noise is required.
Using air bellows as isolators extends machinery life due to their outstanding absorption capability and allows for height control through pressure regulation, guaranteeing a uniform operating height with alternating loads.
Selecting the right series and size
Tevema offers two main series of air bellows, each with distinct characteristics:
D Series
The D Series features single convolution, double convolution, and triple convolution options with dismountable design. These are available in various sizes with external diameters ranging from 80 mm to 700 mm. The D Series is particularly suitable for applications requiring easy maintenance and component replacement.
Key technical specifications to consider:
- External diameter (Ø Max)
- Minimum height
- Maximum height
- Force generation at specific pressure
- Stroke capabilities
- Design height
- Natural frequency (for isolation applications)
F Series
The F Series offers crimped design and bead ring design options, also available in single, double, and triple convolutions. This series provides a wide range of mounting configurations and is known for its robust performance in demanding industrial environments.
When selecting between these series, consider:
- Installation requirements
- Maintenance needs
- Performance expectations
- Budget constraints
Material selection for optimal performance
The material selection for your air bellows significantly impacts their performance and longevity in specific environments. Tevema offers various elastomer compounds to match your operational conditions:
- Natural rubber (NR/SBR): Excellent universal properties with very high dynamic capability. Temperature range from -40°C to +70°C.
- Chlorobutyl material (CIIR): Outstanding acid resistance. Temperature range from -30°C to +115°C.
- Nitrile compound (NBR): Excellent oil resistance, fuel resistance, ozone resistance, and outdoor performance. Temperature range from -25°C to +110°C.
- EPDM material: Excellent resistance to high temperatures, ozone, and outdoor conditions. Temperature range from -20°C to +115°C.
- Chloroprene rubber (CR): Excellent weathering resistance and medium resistance to oils. Temperature range from -20°C to +110°C.
For the metallic components, standard options include electro galvanized steel, but stainless steel options (AISI-304) are available for applications requiring high wear resistance and durability in harsh media such as acids and chemicals.
Pressure considerations and special requirements
Standard construction air bellows operate with a maximum allowable pressure of 8 bar. For applications requiring greater force, Tevema offers a four-ply version with a pressure capability of 12 bar, achieving greater forces for demanding applications.
While air bellows are designed to work with compressed air, they can also operate with alternative working media such as nitrogen, oil, or water. When using water, stainless steel metallic parts are recommended to prevent corrosion.
Installation and maintenance factors
Proper installation is crucial for optimal performance. Consider these factors:
- Mounting options: Evaluate the available fixation methods and ensure compatibility with your equipment.
- Height adjustment: Determine if your application requires height control capabilities.
- Angular requirements: Some applications benefit from the tilt motion capabilities of air bellows (up to 25°).
- Storage conditions: If you’ll be stocking spare units, ensure you have appropriate storage conditions – cool, dark, and dry environments away from direct sunlight or ozone-producing equipment.
One of the significant advantages of air bellows is their maintenance free operation. Unlike conventional cylinders with sliding sealing elements, air bellows offer extended service life with minimal maintenance requirements, reducing both downtime and lifecycle costs.
Cost considerations
When evaluating the cost efficiency of air bellows, look beyond the initial purchasing cost (which is typically lower than conventional pneumatic cylinders) and consider:
- Operational costs: Lower maintenance requirements translate to reduced long-term expenses.
- Extended product life: Air bellows are unaffected by weathering and can be manufactured with various elastomers and steel qualities for use in harsh ambient conditions.
- Extended machinery life: The superior isolation properties of air bellows protect your equipment, extending its operational lifespan.
Making the final decision
The process of choosing the right air bellows involves balancing multiple factors. We recommend following these steps:
- Clearly define your application’s requirements and environmental conditions.
- Determine whether you need an actuator, isolator, or both.
- Calculate the required load capacity, stroke length, and space constraints.
- Select the appropriate series (D or F) based on your maintenance and installation preferences.
- Choose the right size based on your technical parameters.
- Determine the optimal material based on your environmental conditions.
- Consider any special requirements such as higher pressure capabilities or alternative working media.
- Evaluate the total cost of ownership, including initial purchase, installation, and long-term maintenance.
Selecting the right air bellows for your business needs doesn’t have to be overwhelming. By understanding your specific requirements and the various options available, you can make an informed decision that enhances your operations’ efficiency and reliability. At Tevema, we’re committed to providing high-quality industrial air bellows backed by decades of manufacturing experience and technical expertise.
Our comprehensive range of products, coupled with our dedicated technical support, ensures that you’ll find the perfect solution for your unique business challenges. Whether you’re looking for superior vibration control, reliable actuation, or both, our team is ready to help you navigate the selection process and implement the optimal solution.
Remember that the right choice today leads to improved performance, reduced maintenance, and significant cost savings tomorrow. Invest time in the selection process now to reap the benefits of optimal air bellows performance for years to come.