Identifying misalignment during installation
When troubleshooting common air bellows installation issues, alignment is the most frequent problem. We verify that mounting plates are parallel and centered. Uneven surfaces or misaligned fasteners can twist the air bellows and reduce performance. Before pressurizing the system, we ensure all fixations are secure and balanced. A misaligned bellow leads to uneven compression and early wear. We check the rubber surface for bulges or tension marks. These indicate incorrect seating. For multi-convolution units, height checks are essential. Each convolution must expand evenly. We use spirit levels to verify horizontal alignment. If the structure leans, additional supports are required. Mounting holes must not overlap the bellow’s max diameter. If they do, contact between fasteners and rubber can rupture the component. Proper alignment avoids vibration amplification. It also ensures full stroke movement. We recommend documenting each step of installation. That makes diagnosing issues much easier later.
Avoiding air leaks and pressure loss
A very common issue is pressure loss due to air leaks. During installation, we tighten all air inlet fittings to the recommended torque. If over-tightened, fittings may crack the metallic end caps. We apply PTFE tape on threaded connections, avoiding excess that could enter the system. For crimped types, we inspect for damaged seals around the plates. Soap tests reveal even the smallest leaks. We advise technicians to spray soapy water around fittings and check for bubbles. Leaking fittings not only reduce performance but can cause system instability. If the pressure drops below threshold, the air bellow may collapse. We also check compressor and regulator calibration. Incorrect supply pressure may mimic a leak. Valve timing in multi-chamber systems must be synchronized. Leak detection is part of every commissioning checklist. When leaks are identified, the faulty part is removed, cleaned, resealed or replaced. A leak-free system extends component life significantly.
Handling overload and stroke limitations
Overloading is a frequent installation problem that can damage air bellows. We calculate the expected load before selecting the model. If field measurements exceed the design range, we must upgrade the bellow. Over-compression happens when the stroke exceeds its limit. This reduces isolation quality and causes internal ply damage. To avoid this, we measure the design height after pressurization. If it’s below specification, we adjust the pressure or the mounting height. Operating too close to the maximum stroke leads to resonance. That introduces high-frequency vibration and shortens the unit’s lifespan. We also inspect for contact between the bellow and adjacent components. Side contact during expansion is a sign of incorrect spacing. In severe cases, stroke limiters are installed. These mechanical stops protect the bellow from bottoming out. Every installation must respect the stroke range. This ensures the air spring delivers full performance.
Ensuring proper torque on mounting fasteners
Torque irregularities often cause installation failures. Under-torqued bolts may loosen during operation, while over-torqued fasteners damage the flanges. We use calibrated tools to apply the correct torque to each fastener. The torque specifications are defined by the bellow diameter and flange type. For stainless steel flanges, torque limits are lower. Incorrect tightening can deform the end plates or bead rings. Deformation affects the air seal and leads to leakage. For F-series air bellows, we use thread-locking compounds to prevent loosening. We check bolt tension after the first operational cycle. If bolts lose preload, vibration may increase. To distribute torque evenly, we follow a cross-pattern sequence when tightening. Gasket materials must not be over-compressed, as they may crack. We re-torque every 100 operating hours during the first cycle. After that, maintenance intervals can be extended. Torque consistency contributes to safe and stable operation of air bellows.
Verifying mounting surface conditions
Surface preparation is a key part of successful air bellow installation. Uneven or dirty mounting surfaces cause gaps and stress concentration. We always clean surfaces with a non-corrosive solvent. Rust or paint flakes must be removed entirely. For dismountable types, the plate contact area must be fully flush. If gaps exist, rubber deformation will occur. We also avoid sharp edges near the bellow’s base. Sharp surfaces can puncture the rubber structure during expansion. Mounting plates should be made from a rigid material, ideally machined steel or aluminum. Soft or flexible bases will introduce unwanted movement. We inspect for oil residues. Oil can react with rubber and cause softening. Anti-slip coatings are used when vertical alignment is critical. Every installation should include a visual inspection checklist. A perfect surface match improves the seal and ensures long-term durability. We also apply protective coatings to exposed flanges in corrosive environments.