When it comes to air bellows or air springs, proper installation is critical for ensuring optimal performance and durability. Air bellows are widely used in industrial settings for various functions, from vibration isolation to serving as actuators. However, installation mistakes can significantly impact their efficiency and longevity. In this article, we will address the most common errors made during installation and how to prevent them.
Inadequate Pressure Settings
One of the most frequent mistakes we encounter is incorrect pressure settings during installation. Air pressure plays a crucial role in the functioning of air bellows, affecting both their load capacity and response characteristics. If the pressure is set too low, the bellows may not provide adequate force or isolation. Conversely, excessively high pressure can lead to premature wear and even rupture.
To avoid this, we recommend always consulting the manufacturer’s pressure guidelines. For instance, the maximum allowable pressure for standard Tevema air bellows is typically 8 bar. In situations requiring higher pressure, such as when increased load capacity is necessary, Tevema offers a four-ply construction capable of handling pressures up to 12 bar. Proper pressure calibration ensures that the air bellow operates within its intended range, avoiding unnecessary stress.
“An expert is a person who has made all the mistakes that can be made in a very narrow field.” — Niels Bohr
Misalignment During Installation
Misalignment is a common issue that can severely impact the performance of air bellows. If the bellows are not installed correctly in terms of alignment, they may experience uneven stress, leading to reduced functionality and failure. Misalignment can result in side-loading, which conventional air springs are not designed to handle effectively.
To avoid alignment issues, it’s crucial to ensure that the mounting plates are level and positioned correctly. Using a jig during installation can help achieve precise alignment, especially in complex setups. Remember that even small misalignments can lead to increased wear, friction, and failure.
Ignoring Installation Height Restrictions
Another mistake often made is ignoring the proper installation height. Every air bellow has a specified minimum and maximum height range that must be adhered to for safe and effective operation. Operating an air bellow outside of this range can lead to a loss of performance or even physical damage to the unit. For example, Tevema air bellows feature a minimum installation height of 50 mm and a maximum of 430 mm, depending on the model.
To prevent issues related to height, always verify that the air bellow is operating within its intended height limits. Additionally, installing safety stops is a good practice to ensure that the bellows do not exceed their designed height or bottom out during operation.
Improper Support Area
Air bellows require a support area that ensures an even distribution of the load. A common error is installing the air bellow on a surface that is either too small or does not allow uniform load distribution. The complete surface of the rubber bellow should be supported; ideally, at least 65% of the support area should be engaged to prevent localized stress points that could lead to ruptures.
To mitigate this issue, ensure that the support structure is robust enough to carry the load uniformly. This means providing flat, unobstructed surfaces that can bear the forces exerted by the air bellow under operational conditions.
Lack of Stroke Limitation
The stroke of an air bellow should be limited to prevent exceeding its designed movement range. During installation, the air bellows must have suitable stroke limitation mechanisms to avoid over-extension or over-compression. A typical mistake is neglecting these limits, which may lead to damage over time.
To avoid this, install external stops that control the maximum extension and compression of the air bellow. When working as a vibration isolator, it’s also recommended to use horizontal stops to achieve complete isolation without excessive lateral movement.
“The only real mistake is the one from which we learn nothing.” — Henry Ford
Exposure to Sharp Objects or Abrasive Surfaces
One of the simplest yet most impactful mistakes is positioning air bellows too close to sharp or abrasive surfaces. The rubber material used in air bellows can easily be punctured or worn down if it comes into contact with such surfaces. This can happen either during initial installation or during operation as the bellows expand and contract.
To prevent this, inspect the installation area carefully and ensure that there is adequate clearance around the bellows. The surrounding space should be free of any potentially harmful objects, and the air bellow should have enough room for full expansion without chafing.
Using Incorrect Fasteners
The type of fasteners used during installation is another crucial factor. Using incorrect fasteners, such as bolts that are either too short or too long, can lead to insufficient attachment or, worse, damage to the air bellow’s structure. For Tevema air bellows, always use the specified mounting hardware and ensure they are torqued to the correct specifications, typically between 15 to 20 ft-lbs for blind nuts.
Additionally, we suggest periodically checking the fasteners for tightness as part of regular maintenance, especially in applications where vibration is prevalent.
Environmental Considerations
Environmental factors such as temperature, exposure to chemicals, or UV radiation can also impact air bellow performance. Installing air bellows in environments outside their recommended temperature range can compromise the elastomer compounds used in their construction. For example, Tevema bellows made of natural rubber are designed to operate between -40°C to +70°C.
Ensure that the air bellows selected are suitable for the specific environment in which they will be used. For high-temperature or chemically aggressive environments, consider using bellows made from chlorobutyl or nitrile materials, which offer better resistance to harsh conditions.
Conclusion
Proper installation of air bellows is crucial for maximizing their efficiency and lifespan. By avoiding common mistakes such as misalignment, incorrect pressure settings, ignoring height limits, and using improper fasteners, we can ensure that our Tevema air bellows function effectively across various applications. Careful attention to detail during installation helps prevent unnecessary downtime, reduces maintenance costs, and extends the operational life of the equipment.