In our industry, durability of air bellows is critical to ensure reliable performance under extreme conditions. Whether they are used for industrial machinery, vibration isolation, or vehicle suspension, air bellows, also known as air springs, must withstand demanding operational environments. Today, we’ll explore how Tevema air bellows deliver exceptional durability, even under the harshest conditions.
What Makes Air Bellows Durable?
Air bellows derive their durability from several key factors, including the materials used, construction techniques, and design considerations. At Tevema, we ensure that every air spring is built to endure the pressures, temperatures, and mechanical stresses that characterize extreme operating environments.
High-Quality Material Selection
The first and most significant aspect of air bellow durability is the material quality. Tevema uses a mix of high-grade elastomers, including natural rubber (NR/SBR) and chlorobutyl. These materials provide an excellent balance of flexibility, temperature resistance, and tensile strength, essential for performance in both cold and hot environments.
Moreover, we offer different elastomer compounds for specialized applications, such as nitrile (NBR), which is highly resistant to oil and fuels, making it ideal for certain industrial uses. The four-ply reinforced design also contributes to the durability, enabling the bellows to handle higher pressures, up to 12 bar, while reducing the chances of wear and tear.
“The material must be suited to its intended use, or the entire structure’s reliability comes into question.” — Henry Petroski
Temperature Extremes and Resilience
Air bellows often operate under extreme temperatures, and the resilience of Tevema’s air bellows against thermal changes is remarkable. Depending on the rubber compound, our air springs are suitable for temperatures ranging from -40°C to +115°C. This resilience makes them suitable for applications where there are significant temperature fluctuations, such as outdoor machinery exposed to winter cold or high-heat environments within industrial processes.
Our chlorobutyl air bellows provide extended thermal resistance, making them particularly effective in applications requiring continuous operation at elevated temperatures. In contrast, natural rubber bellows work well in standard industrial settings, offering an optimal cost-to-performance ratio.
Effective Noise and Vibration Isolation
Another factor that plays a role in the durability of air bellows is their ability to isolate noise and vibration effectively. Air bellows by Tevema can isolate over 99% of unwanted vibrations, reducing mechanical fatigue on the air spring itself and the surrounding components. This vibration isolation also extends the life of other mechanical components, thereby improving the overall lifespan of the machinery in which they are used.
Pressure Management and Structural Integrity
The maximum allowable working pressure for most Tevema air bellows is 8 bar, which can be extended to 12 bar for our four-ply variants. It is crucial to note that maintaining the right pressure range not only ensures optimal performance but also prevents premature failure due to over-inflation.
We recommend using safety stops and stroke limitations to prevent the air actuator from exceeding the maximum allowable working height or from bottoming out during compression cycles. This practice significantly enhances the durability of the air springs by preventing them from being overstressed during operations.
Guidelines for Installation and Operation
Proper installation plays a vital role in enhancing the lifespan of air bellows. We advise that support areas must provide uniform load distribution to prevent localized stress, which could lead to tearing of the rubber material. Furthermore, ensuring sufficient clearance to avoid rubbing against sharp surfaces is essential during installation.
“Durability is not just about what you build; it is about how well you maintain and manage the conditions.” — James Watt
Durability in Extreme Operational Conditions
Low Temperature Performance
In freezing conditions, the flexibility of the air bellows can be compromised. However, Tevema’s air bellows are designed to maintain flexibility even at -40°C, ensuring reliable performance in winter operations or high-altitude applications. The use of chloroprene elastomer is particularly effective for weathering resistance, allowing the air spring to maintain its operational integrity without cracking or becoming brittle.
High Temperature and Corrosive Environments
For high-temperature applications, ethylene propylene diene (EPDM) rubber bellows are the best choice, providing temperature resistance up to +115°C. In corrosive environments, we also provide stainless steel end plates (AISI-304 or AISI-316L), which significantly extend the operational lifespan by preventing rust and corrosion.
Maintenance Practices that Prolong Life
To further improve durability, routine inspection and maintenance are essential. Tevema air bellows are designed for minimal maintenance. However, it is advisable to regularly check for wear, alignment issues, and proper pressure settings. Any visible damage to the elastomer or fittings should be addressed immediately to prevent total failure.
Auxiliary Reservoirs
Adding an auxiliary reservoir can improve the efficiency and longevity of the air bellows by increasing the volume and subsequently decreasing the natural frequency. This method reduces fatigue on the air spring when it operates in high-vibration environments.
Real-World Applications: Extreme Conditions
Tevema air bellows are deployed in a variety of applications where durability is put to the test. For instance:
- Off-Road Vehicles: Subjected to heavy impacts, our air bellows are chosen for their ability to withstand rugged conditions while maintaining suspension performance.
- Heavy Machinery: In factories, air bellows must endure constant loads and vibration, withstanding the pressures of short stroke high-thrust applications without wearing down quickly.
- Agricultural Equipment: Operating in fields means exposure to dust, dirt, and extreme weather, and our four-ply bellows have shown exceptional resistance in these conditions.
Conclusion
The durability of air bellows in extreme conditions is a testament to quality engineering, advanced materials, and thoughtful design. Tevema’s air bellows stand out due to their high resilience, broad temperature range compatibility, and ability to manage high pressures. By following best practices for installation and maintenance, their lifespan can be significantly extended, providing both reliability and cost-efficiency.
The performance of Tevema air bellows in applications ranging from vehicle suspensions to industrial vibration isolators ensures our customers have a dependable product that meets the rigorous demands of modern engineering environments.