Pneumatic cylinders are essential components in pneumatic systems, converting compressed air into linear movement to translate force linearly. They power millions of industrial processes, from automation systems to factory equipment. However, improper installation can cause equipment failure, reduced performance, or even safety hazards.
In this tutorial, we will guide you through proper pneumatic cylinder installation and maintenance, with key considerations and safety precautions to ensure optimum operation and lifespan.
Why Does Proper Installation Matter?
There are various problems caused by improperly installed pneumatic cylinders, including:
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Unreliable or ineffective operation
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Early equipment failure
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Increased risk of machine damage
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Threats to operator safety
That is why proper procedure and manufacturer instruction need to be followed in the process of installation.
What Do You Need to Consider Before Installation
Pneumatic cylinders are mounted much the same way as hydraulic cylinders, but the installation style depends upon mounting style and application.
Focus on Two Major Parts:
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The Cylinder Body
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The Piston Rod End
Mounting of these parts differs depending on the specific motion and force requirements of your system.
Most applications are either one of two types:
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Static Applications
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The cylinder is rigidly mounted to a machine or bench.
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Dynamic/Linkage Applications
The cylinder will have to swivel or turn when in use, so there has to be flexible mounting.
Rodless cylinders or other designs can have special requirements, so always consult the manufacturer's fitting instructions.
Pneumatic Cylinder Installation
While every application will be unique, there are certain universal concepts that don't change:
Don't side load: This is when forces are applied laterally to the piston rod, resulting in excessive bearing wear and potential failure.
Proper alignment: Misaligned installations put friction on, reduce efficiency, and damage the cylinder.
Mounting specifications: Choose the right mounting type (flange, trunnion, clevis, etc.) based on your system requirements.
Key Installation Considerations
The following are some key guidelines to follow when mounting pneumatic cylinders:
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Minimize or eliminate side loading
Precisely align the cylinder. Use alignment couplers or die-set couplings to reduce rod end stress.
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Lubricate moving components
Lubricate trunnions and bearing slides according to manufacturer guidelines.
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Avoid unsupported loads on piston rod
Use external support (e.g., slides, roller guides) for heavy or offset loads.
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Restrict bending moments
Bending moments are caused by too much extension because of the piston rod's weight. Use a roller track to support the rod end, if possible.
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Use conditioned clean air
Supply filtered, dry air to your system to prevent damage. Particle filtration and removal of moisture are required in most systems.
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Adjust the horizontal mounting of a rear-hinged cylinder
If a rear-hinged cylinder is horizontally mounted, body weight will create a bending moment. Use a central trunnion as support and counterbalance.
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Testing Prior to Operation
Before putting your pneumatic system into operation:
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Test with a blow gun and flexible airline on the setup.
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Check that the cylinder glides smoothly at the minimum required pressure.
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Check that the full range of motion is clear and correctly aligned.
This final step ensures the cylinder is in the correct position and ready for reproducible service.
Need Help Choosing the Right Cylinder?
Are you seeking world-class pneumatic cylinders? HAK Fluid Power Equipment LTD is here to serve. Based in Toronto, Canada, we provide reliable, industry-grade pneumatic solutions capable of fulfilling your system's needs.
Call us today and speak with our experts and see our full line of pneumatic equipment.