Step-by-Step Guide to Installing Air Bellows

Air bellows, also known as air springs, are an essential component for industrial applications, providing efficient vibration isolation and supporting heavy loads with precision. In this guide, we will walk you through the complete installation process for air bellows, emphasizing practical tips and crucial considerations to ensure a successful installation. Proper installation is key to achieving the best performance and durability of your air bellows.

Tools and Materials Needed

To install the air bellows, you will need the following tools and materials:

• Torque wrench
• Assembly jig (recommended for precise installations)
• Mounting bolts, washers, and nuts
• Measuring tools (tape measure and calipers)
• Air compressor for inflating the air bellows
• Safety stops (optional but recommended)

1. Pre-Installation Checklist

Before starting the installation, it is crucial to check that all components are in place and free of damage. Inspect the air bellows for any visible tears, cracks, or worn-out areas. Ensure that the mounting plates, bead rings, and fasteners are suitable for the chosen bellows type, whether crimped or removable.

Important Considerations:

• The support area must be uniform to ensure an even load distribution. Ideally, use 100% of the support area for optimal performance.
• If dealing with multiple bellows units, ensure they have consistent alignment and proper positional tolerances.

2. Proper Positioning of Air Bellows

When positioning the air bellows, ensure that they are vertically aligned and free of angular misalignment. Misalignment can lead to premature wear or failure of the bellows. It is also important to maintain sufficient clearance to avoid chafing, which can damage the rubber bellow.

Installation Space Requirements

• Height Considerations: Ensure that the air bellows have enough height for both the compressed and extended states. The installed height should match the specifications in the technical datasheets.
• Surrounding Clearance: Make sure that there is enough space around the bellows at its maximum diameter to prevent contact with sharp surfaces or nearby components.

“The true measure of a machine’s longevity lies in the care we give it during assembly.” – Isaac Newton

3. Mounting the Air Bellows

Air bellows can be mounted using crimped bead plates or bead rings, depending on the application. Here is a step-by-step breakdown of the mounting process:

Step-by-Step Mounting Procedure

1. Attach the Lower Plate: Secure the air bellows to the lower mounting plate using bolts and nuts. If using crimped bead plates, make sure to tighten bolts to the specified torque (usually 15-20 ft-lbs).
2. Positioning with Assembly Jig: Use an assembly jig to align the axle set precisely if multiple bellows are used. The jig ensures the dimensional tolerances are complied with for an accurate and reliable fit.
3. Install the Upper Plate: Align the upper mounting plate with the air bellows and secure it with bolts. Use washers and torque the bolts to the manufacturer-recommended values to prevent damage.

Tip: If a stud adapter is preferred, it can be used in place of blind nuts for ease of installation.

4. Connecting the Air Inlet

The air inlet is critical to ensure the proper functioning of air bellows. Connect the air inlet to a regulated air supply, making sure to use an appropriate fitting.

• The standard air inlet size is typically 1/4″ NPT but can vary based on the bellows size.
• Do not exceed the recommended pressure of 8 bar for standard bellows or 12 bar for high-strength versions.

Ensure that all connections are airtight to prevent leaks that could compromise performance. Regularly check for any sign of air leakage during operation.

5. Safety Stops and Stroke Limitations

To prevent overextension or bottoming out of the bellows, it is recommended to use safety stops. These stops can protect the air spring by limiting its range of movement and preventing structural damage.

Horizontal Stops

When air bellows are used as vibration isolators, horizontal safety stops help maintain isolation properties while ensuring that the unit does not shift excessively during operation.

“An ounce of prevention is worth a pound of cure.” – Benjamin Franklin

6. System Testing and Final Checks

After installation, the air bellows system should be tested thoroughly to confirm its functionality.

• Inflation Test: Gradually increase the air pressure and check for smooth and even expansion. Ensure there are no areas of binding or excessive stretching.
• Load Test: Place the intended load on the air bellows to evaluate performance. Observe the system for any height discrepancies or signs of misalignment.
• Leak Test: Inspect all air connections for possible leaks using a soap solution. Bubbles forming around connections indicate an air leak that must be corrected.

7. Maintenance and Care Tips

Proper maintenance is essential for extending the life of your air bellows:

• Regular Inspections: Conduct visual inspections regularly to detect early signs of wear or damage.
• Maintain Operating Pressure: Keep the air pressure within the specified range. Over-pressurizing the bellows could lead to bursting, while under-pressurizing could result in instability.
• Environmental Protection: Ensure the bellows are not exposed to extreme environmental conditions. For applications involving chemicals or acids, consider using stainless steel end fittings.

Conclusion

The correct installation of air bellows is crucial for achieving peak performance and longevity. By following the steps and guidelines outlined here, you can ensure that your air bellows provide reliable, maintenance-free service for years to come. Remember, proper mounting, alignment, and regulated air pressure are the foundations of successful air bellows operation.