Preparing the system for safe inflation
Correct inflation techniques begin with system preparation. Before inflating any air spring, we verify that all mechanical connections are secure. Mounting bolts must be torqued to the manufacturer’s specifications. We check that air inlets are clean and free of debris. Improper sealing or dirt in the fitting may cause internal abrasion or pressure loss. The air source must be regulated and equipped with a pressure gauge and shut-off valve. We also confirm that the bellow is not under any load before inflation begins. Load-bearing during inflation may stretch the rubber element unevenly. If the system includes multiple units, all valves must be in the closed position except for the one under inflation. This ensures equal and controlled pressure buildup. The work area is cleared and safety barriers are put in place to protect personnel. These procedures reduce the risk of unexpected movement or overpressurization.
Inflating gradually to reach design pressure
Key to proper inflation is applying pressure gradually. Sudden inflation can damage internal plies and cause uneven expansion of the air bellows. We recommend using a slow-fill valve or regulator to bring pressure up in steps. Starting at 0.2 bar, we increase pressure by 0.2 bar increments while monitoring the bellow’s shape and height. At each level, we inspect for side bulging, uneven inflation, or leaks. If abnormalities occur, inflation is stopped immediately for inspection. Once the bellow reaches its design height, we measure pressure at the inlet port to confirm it matches the specified operating range. For standard units, this typically lies between 4 and 8 bar. Units designed for high load may operate at up to 12 bar. Exceeding this pressure voids product warranty and introduces failure risk. When the correct pressure is reached, we close the valve and lock off the system to prevent further fluctuation.
Checking alignment and movement during inflation
A critical step in inflation techniques is checking alignment during pressurization. We observe the air spring for lateral shift or tilting as it expands. Misalignment during inflation indicates an uneven mounting surface or incorrect bracket orientation. If misalignment is seen, we deflate the unit, correct the base, and restart the process. We use a spirit level to confirm that the top and bottom plates remain parallel throughout the inflation cycle. For multi-convolution bellows, each convolution must expand simultaneously and evenly. Asymmetrical expansion reduces durability and alters dynamic response. We also check for contact with adjacent surfaces. The air spring should expand vertically without friction or obstruction. Any contact point may puncture the bellow or cause material fatigue. We avoid using tools during this phase, as physical interference introduces damage risk. A proper inflation check ensures the spring will perform as intended in dynamic applications.
Testing system pressure stability after inflation
After completing the inflation techniques, we verify system pressure stability. We observe the pressure gauge for a minimum of 10 minutes without load change. A pressure drop indicates a leak, which must be traced and repaired. We use a soap and water solution to inspect fittings, plates, and rubber interfaces. If no bubbles appear, we confirm the unit is sealed. Once sealed, the system is tested under simulated working conditions. This includes introducing load gradually and monitoring air spring height and responsiveness. If the spring collapses or shows delayed expansion, it may be under-pressurized or structurally compromised. In such cases, pressure levels are recalibrated, or the component is replaced. For installations with height control systems, we verify sensor and valve timing after pressurization. Stability tests are logged, and a final inspection is signed off by the responsible technician. Stable inflation is the foundation for safe and reliable long-term operation.
Final checks and commissioning procedure
Once inflation techniques are completed, we finalize the commissioning procedure. We document the installed pressure, component serial numbers, and torque levels on all fixings. All valves are returned to their operating positions. In multi-bellow systems, we balance pressures between units using a cross-check gauge system. Uneven pressure distribution can reduce load sharing and increase wear. For safety-critical applications, we install pressure relief valves to protect against accidental over-pressurization. Visual indicators may also be used to signal deflation or over-expansion. The entire system is cycled three times before being handed over to production. During each cycle, we observe for abnormal behavior or response delay. Upon successful repetition, the unit is approved for operation. Operator teams are instructed on basic checks and shutdown protocols. Properly executed inflation and commissioning enhance performance, prevent early failure, and ensure that air springs deliver optimal functionality from day one.