In automation systems, air bellows offer a unique advantage when precision, vibration reduction, and mechanical flexibility are required. Rather than relying solely on rigid pneumatic or hydraulic cylinders, we integrate air bellows to benefit from their vibration isolation and actuation properties. Choosing between air bellows as actuators or isolators depends on the intended mechanical function and environmental demands. Understanding the distinctions allows us to design better automation systems that are more durable, cost-effective, and performance-driven. The typical operating pressure range for standard bellows is up to 8 bar, while high-strength versions can handle up to 12 bar. Load capacities vary per configuration and reach up to 380 kN per unit. Materials used in air bellows include multiple fabric-reinforced plies, often in single, double, or triple convolution formats. Our focus remains on engineering systems that are efficient, precise, and built to last under demanding industrial conditions.
Why choose air bellows as actuators?
When we consider air bellows as actuators, we’re selecting a solution known for its long lifecycle, no-stick operation, and multi-directional flexibility. These rubber-based components operate without sliding seals, eliminating internal friction. As a result, we avoid the stick-slip effect that often limits the precision of traditional cylinders. Air bellows offer uniform movement, even under variable pressure, while accommodating lateral misalignment and tilt angles up to 25°. This reduces our dependence on precision guides. In compact spaces, they perform exceptionally well due to their low design height, making them ideal for applications where space is limited. Actuation forces range from 2.4 kN to 248 kN at 7 bar. Stroke values extend from 20 mm to over 400 mm, depending on the model. The effective area defines the resulting force, calculated using pressure and geometry. These characteristics make them robust for pressing, lifting, or vibration-damped axial motion.
Benefits of using air bellows as isolators
As vibration isolators, air bellows achieve up to 99% vibration absorption, protecting our machinery from harmful oscillations. This is especially useful in sensitive automated environments where component longevity is critical. Their uniform isolation performance, regardless of load changes, ensures a stable operating environment. Bellows provide low natural frequencies, down to 1.2 Hz, effectively decoupling equipment from external vibrations. They perform consistently across a wide load spectrum, maintaining performance from 0.5 kN to over 300 kN. By minimizing structural-borne noise, air bellows help us maintain quieter production floors. Their constant natural frequency allows consistent isolation even with varying weights. Additionally, they support dynamic air pressure tuning to maintain steady height under fluctuating loads. Materials used can withstand extreme ambient conditions, such as -40°C to +115°C, depending on the elastomer. Their extended lifespan and maintenance-free nature reduce operating costs and minimize unplanned downtime in production environments.
Design considerations in actuator configuration
When designing actuator systems, we focus on selecting the correct convolution type: single, double, or triple. Each type affects stroke length, force output, and compactness. A single convolution bellow delivers fast response with minimal space, while triple convolution models allow for greater movement range and load capability. Stroke values range from 30 mm to 400 mm, and the natural frequency at 6 bar spans from 1.2 Hz to 4.6 Hz, depending on geometry. We also consider the mounting design. Dismountable options in the D series allow easy maintenance with clamping bead rings, while crimped versions offer permanent assembly. Materials used for mounting include galvanized steel, aluminum, and stainless steel AISI-304. Actuators may require offset tolerance, and rubber bellows support this through flexibility in all directions, reducing stress on connected equipment. Whether it’s pressing operations, clamping, or height control, our actuator configurations remain consistent under pressure.
Engineering air bellows as isolators
For isolator use, our goal is to reduce resonance amplification and enhance machine stability. Choosing the right natural frequency range is crucial. With air bellows, we achieve values as low as 1.2 Hz, outperforming steel coil or rubber mounts. We match load capacities to specific configurations, ranging from 8 kN to 380 kN per unit. Design height and stroke influence the damping effect, with some models offering a height variation up to 300 mm. In automated systems with frequent load variations, we benefit from pressure adjustability, enabling real-time tuning of isolation properties. These bellows help prevent hard mechanical coupling by offering uniform flexibility. They absorb shocks, limit impulse transfer, and ensure consistent damping performance across different machine platforms. By choosing air bellows as isolators, we protect sensitive automation components, increase the lifespan of high-precision equipment, and ensure operational reliability in dynamically shifting load environments.
Choosing the right elastomer compound
Our choice of rubber compound depends on environmental and chemical exposure. For general use, we rely on natural rubber (NR/SBR) for its high dynamic load capacity. In acidic environments, chlorobutyl (CIIR) resists chemical degradation. For oil exposure, nitrile (NBR) provides long-term resistance. Where ozone, UV, and temperature extremes are concerns, EPDM and chloroprene (CR) offer weatherproof solutions. Each compound is available with reinforcing fabric plies, enhancing strength and fatigue resistance. We often pair these with AISI-304 or AISI-316L stainless steel end plates for use in cleaning-intensive or chemical-prone industries. The operating temperature range spans from -40°C to +115°C, depending on material selection. Our elastomer strategy supports load variation, thermal cycles, and abrasion exposure. This ensures long-term performance and minimal deformation. Selecting the right elastomer ensures durability, minimizes downtime, and supports consistent performance. Our approach guarantees that air bellows remain reliable regardless of external stressors.
Advantages of dismountable and crimped designs
The D Series dismountable design simplifies replacement and installation, reducing machine downtime. These models use top and bottom plates clamped with bead rings, including threaded holes for easy integration. They’re ideal for automation lines with frequent maintenance cycles. Typical plate materials include galvanized steel, anodized aluminum, and optionally AISI-304 stainless steel. Port threads vary by configuration, including G1/4″, G3/8″, and G3/4″ for different air flow requirements. In contrast, F Series crimped types provide a sealed assembly, perfect for permanent installations. They’re more compact and leak-resistant due to their integrated structure. The design height of crimped bellows starts from 50 mm, supporting strokes over 100 mm. We configure these systems based on the required force, installation dimensions, and connection patterns. Understanding these design differences ensures we implement the best fit for every automation requirement, balancing flexibility, serviceability, and durability in every installation.
Controlling height and force output
To maintain operating height, we adjust internal air pressure. This makes air bellows ideal for applications where load changes dynamically. Whether functioning as an actuator or isolator, the bellow’s geometry ensures predictable vertical movement. For actuator tasks, we calculate force using pressure and effective area. At 7 bar, bellows can deliver forces ranging from 2.4 kN to 248 kN, depending on the model. We rely on stroke data, diameter specs, and natural frequency to match performance to application. In isolator roles, maintaining the correct pressure ensures the natural frequency remains stable, which is essential for resonance avoidance. We configure air supply systems with pressure regulators to support precise control. Bellows allow for height adjustments from 30 mm up to 400 mm, depending on the construction. Thanks to this flexibility, air bellows integrate seamlessly with automation controllers, PLC systems, and smart sensors, giving us real-time oversight of mechanical behavior.
Storage and handling guidelines
Proper storage ensures air bellows remain in excellent condition prior to installation. We keep them away from ozone-producing equipment, direct sunlight, and extreme temperatures. Following ISO 2230, we store bellows in cool, dry, and dark conditions. Storage temperature should remain between 10°C and 25°C, and bellows must be shielded from mechanical stress. Before installation, we inspect for surface damage, rubber cracking, or deformation. We only use mounting bolts and plates with compatible thread types to prevent sealing issues. Using original design specifications avoids misalignment and premature wear. We always handle air bellows by their metallic parts, avoiding excessive compression during transport. This preserves membrane integrity and ensures that the bellows retain their full operational range. Proper handling ensures mechanical performance, alignment, and leak-free operation during commissioning. By following these practices, we extend the lifespan, improve operational safety, and maximize the investment in every air bellow we deploy in our automation environments.
Final thoughts on actuator vs isolator
Choosing between air bellows as actuators or isolators depends on our functional goals. As actuators, they deliver precise axial movement, compact installation, and multi-axis tolerance. As isolators, they provide industry-leading vibration reduction, load independence, and noise damping. In both configurations, the flexibility of materials, pressure adaptability, and mounting options give us the engineering freedom to tailor air bellows to our specific automation scenarios. Their ability to function in harsh environments, coupled with low maintenance demands, makes them a smart, future-ready investment. Their capabilities cover loads from 0.5 kN to 380 kN, strokes from 30 mm to 400 mm, and natural frequencies down to 1.2 Hz. By integrating air bellows thoughtfully, we enhance our systems with better performance, durability, and cost-efficiency.