Pneumatic cylinders, or pneumatic actuators, are essential components in millions of automated equipment, transferring rotary or linear motion and force. With correct integration and proper maintenance, these cylinders deliver long-term, reliable performance. However, even with diligent maintenance, pneumatic cylinders do fail occasionally, resulting in downtime and potential safety hazards or costly downtime.
Understanding the most common causes of failure can help you implement preventive measures and extend the life of your equipment. In what follows, we consider primary causes of pneumatic cylinder failure and how to prevent them.
1. Contamination
The system can be contaminated with oil, water, and particulate matter ingested from the operating environment or the air supply. All of these impurities have the capability to clog internal components, deteriorate performance, and lead to complete failure.
Water or oil buildup can destroy the finish on the barrel or piston rod and impede airflow. To avoid unexpected downtime, see that your pneumatic system is properly filtered and filters are changed as per specs.
2. Side Loading
Side loading occurs when pressure is applied at an angle to the cylinder axis, rather than in a straight line. This misalignment can lead to:
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Seal failure
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Increased bearing wear
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Scoring of the cylinder tube
Improper mounting is most often the root of side loading. When such an issue arises, the cylinder can be fixed or even replaced. Ensure that all cylinders are aligned and mounted with the appropriate tools and accessories.
3. Synchronization Issues
Most contemporary automation requires more than one cylinder to be synchronized to operate in harmony. When synchronization fails, there is an uneven motion and greater stress on the components, leading to premature wear or failure.
To avoid this, ensure synchronization techniques—mechanical or electronic—are accurately calibrated and serviced.
4. Inadequate Lubrication
Lubrication is essential for seal integrity. In its absence, seals become desiccated, friction rises, and the possibility of total failure grows. Inspection should involve a review of lubricant levels and the seal condition.
5. Operating Beyond Design Specifications
Each pneumatic cylinder also has load and pressure specifications that it can handle. Too heavy loads or pressures stress internal components, reduce performance, and eventually lead to failure. Always remain within parameters that the manufacturer has specified.
6. Air Leaks
Leaks are a normal consequence of wear and tear. Leaks usually arise at seals, fittings, or hoses. All connections and actuators should be inspected regularly by technicians, particularly after system initialization. Worn-out parts should be replaced immediately to avoid loss of efficiency and equipment stress.
7. Poor Maintenance
Neglected maintenance is one of the main causes of system failure. Daily inspections, visual checks, and occasional reading of maintenance histories can pay big dividends in catching troubles early and extending the life of cylinders.
Best Practices to Reduce Pneumatic Cylinder Failures
For optimal operation of your pneumatic cylinders, follow the following preventive practices:
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Perform routine visual inspections. Walk through your equipment and check for wear, damage, or leaks.
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Install cylinders properly. Use the correct tooling and follow the alignment procedures with attention.
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Seal and inspect for rust on fittings. Rusty or improperly installed fittings can introduce contaminants into the system.
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Change filters as recommended. Follow the manufacturer's schedule to maintain air quality at its highest level.
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Follow torque specs. Over-torquing will ruin components just as easily as under-torquing.
Looking for High-Quality Pneumatic Cylinders?
If you require high-quality pneumatic cylinders for your use, HAK Fluid Power Equipment LTD offers the full range of solutions tailored to deliver high performance and durability. Contact us today and learn about the right product for your application.