Performing repeatable tasks with 100 percent accuracy is impossible in almost all industrial automation. However, air cylinders can make it efficient by using air pressure to do the job.
However, these excellently performing air cylinders often leave people questioning when installing them. The air cylinder installation process may look difficult, but it is easy if you pay attention to the details.
This article provides a detailed guide on how to connect air cylinders and the safety precautions to install.
Understanding Air Cylinder Components
Before jumping into connecting a compact air cylinder, it is important to know about the components of the cylinder and what they are used for. Each component mentioned below is crucial for the cylinder to work smoothly.
Cylinder barrel
The cylinder barrel is a tube-like component that holds everything together. It is the body’s main part, and inside it is a piston that lets the cylinder do its work. A cylinder barrel puts everything in place inside itself and protects the components.
Piston
The piston makes the cylinder act. When the air pressure goes inside, the piston moves in a back or forth direction. With this movement, the cylinder lifts, pushes, holds, or places the object. The piston is the main part that creates the force to make the cylinder perform the specific task.
Rod
It connects the piston to the outside of the machine or equipment. Rods are the cylinder parts that stick out of the piston and push, pull, lift, or place the object.
End caps
They are the seals for cylinders, present on both sides. Through the end caps, no dirt and debris can enter the cylinder. It also prevents the air from getting out of it and maintains the air pressure. End caps often have a port, the small opening that lets the air flow in or out.
Ports
They are the small openings on end caps that allow the air to pass through. This airflow controls the piston’s movement and allows the cylinder to operate.
Cushions
When the piston reaches the end of its stokes, it might start acting up and lead to wear and tear of components. However, they absorb the shocks and help save the components from the impact of the piston when it doesn’t function properly.
Seals
Seals are the key part of the cylinder and stop the air pressure from flowing out. They ensure the systems maintain the proper air pressure and work efficiently.
Pre-Installation Considerations
Before installing the cylinders directly, there are a few factors to consider to make the right choice.
Selecting the Appropriate Cylinder
The most essential thing is choosing the one that matches your requirements and meets your needs. Otherwise, there is no point in using the air cylinder.
- Choose the size of the cylinder according to your needs. Sometimes, small pneumatic cylinders may not be able to generate enough force to complete the task. However, a big one will need more energy and effort.
- Look for enough stroke length that fits your requirements. A cylinder with longer strokes can consume extra space.
- If you need the cylinder to lift heavy weights, make sure that you choose the one that is built with the material to handle the force.
- The environment also affects the cylinders. Some work better in the hot, and some in the cold. So, choose the one that can resist the outer temperature.
Ensuring Compatibility with the Pneumatic System
- Go for the cylinder with the pressure rating to handle the air supply. It is important to consider this before installation because using the cylinder with the wrong rating can lead to failure.
- If the cylinder is in contact with the chemical, choose one with materials like corrosion-resistant alloys.
Required Tools and Material
To install the cylinders, the following are the tools you will need to make the process faster, easier, and more efficient.
- Wrenches
- Screwdrivers
- Pneumatic fittings
- Tubing
- Thread seal tape
- Lubricants
- Air supply source
Connection Process: Step-by-step Guide
It might be difficult to install a cylinder, but breaking the air cylinder connections process into small steps can make it easier and smoother.
Mounting the Cylinder
The first step is to place the cylinder in the position you need. Use brackets, clamps, or other mounting fixtures. The mounting should be stable so the cylinder won’t move while operating.
Make sure that the cylinder is aligned. The rod shouldn’t bend down and be in a straight line.
Connecting Air Supply Lines
Now, attach the cylinder ports and air supply lines. It will allow the air to pass through the cylinder.
Using proper pneumatic fittings to connect the tubes will keep them secure. Use thread seal tape (Teflon Tape) to save the cylinder from air leaks. This will help maintain the air pressure and ensure that it works smoothly.
Adjusting Cushioning and Air Stroke Length
Cushion adjustment screws are on the end of the end caps. You can turn these screws to manage how much shock the cylinder can absorb by the end of each stroke. You can also adjust the stroke length to meet your requirements.
Installing Control Valves
Now, connect the control valves to the air cylinder to help control the airflow. It makes the piston move in the desired direction.
If these valves aren’t the right size for your requirements, they will not work properly. So make sure to choose the right size and shape.
Testing the Pneumatic System
It’s time to test the pneumatic system. Start by slowly and carefully adding air to the system. Don’t turn on the full pressure at once, as it can be dangerous if there are loose air cylinder connections.
Look for any hissing sound around the connection, as they can leak the air. You can also use soapy water, so bubbles will show leakage. Try moving the piston from one place to another and see if it functions smoothly. If it makes any unusual sound, you should recheck the installation.
Safety Precaution in Installation
Any negligence in safety can cause harm to the system or the people working with it. But the following are some safety precautions you can use to save yourself.
- Initially, all the air pressure is released from the system. Otherwise, the sudden air pressure can cause any component to fly out and lead to injury.
- Use goggles and gloves to protect your eyes and hands from dust, debris, or any air burst. It can reduce the risk of injuries while installing the cylinder.
- Ensure the proper wiring to prevent electric shocks.
- Keep your hand away from moving parts. Sudden air pressure on the piston can lead to injuries.
- Install the cylinder in a clean, dry place. A clean and tidy workplace will keep everything organized and avoid mistakes.
Common Challenges and Trouble Shooting
Sometimes, issues may arise even after proper installation. But there is always a way to fix all air cylinder connections issues.
Air leaks
If you see any air leakage, check all the fittings and seals. Tighten all the loose connections, but do not over-tighten them. If the seals are damaged or worn out, replace them immediately.
Erratic Cylinder Movement
If you notice any jerky motion of the cylinder is not working smoothly, look for any blockage. Double-check that the cylinder is properly lubricated; otherwise, it can cause friction and unusual movement.
Pressure Loss
Check the air supply if the cylinder is still not working properly. It should put enough pressure on the needs of the population. Leaks can also cause the pressure to slow down. So try to fix it first.
Misalignment
Misalignment in the cylinder can make the rod bend down or wear out. Ensure the cylinder is in a straight line, and on any bend or curve, fix the alignment issue.
Final Thoughts
As the air cylinder is beneficial, its installation is more effective if you follow all the steps and the necessary precautions. But before the installation, ensure you choose the right type and know how to connect air cylinders. Its installation will make your long task much faster.
Choose Foye as your reliable brand for investing in air cylinders. They are a trustworthy supplier that provides the easiest installation of pneumatic air cylinders. With minimal downtime, Foye is leading the market by offering long-lasting product performance.
FAQs
What is the main purpose of air cylinders?
Air cylinders are used to convert air pressure into mechanical motion. You can use them for lifting, holding, arranging, and placing objects without making any errors.
What do I do if my air cylinder doesn’t match the requirements of my task?
If your current air cylinder does not fulfill your requirements, you can always upgrade it. The advanced features in the updated cylinder will surely meet your standards.
What is the role of cushioning in an air cylinder?
Cushions absorb the shocks at the end of each stroke of the piston. They save the other components by reducing the irregularities of the piston and making the cylinder work smoothly.
What few measures can increase the air cylinder’s life span?
If you wish to increase the lifespan of the air cylinder, check for leakages and lubrication. Make sure to clean the outer environment of the cylinder along with the alignment.
Is it okay to test the air cylinder at the highest air pressure?
It is neither safe nor good for cylinders to be tested with high air pressure. But testing them releases all the air pressure because it can cause wear and tear, or the sudden pressure can make a part of it fall out.