In the realm of industrial applications, air bellows play a crucial role in providing effective vibration isolation and actuation solutions. At Tevema, we have dedicated ourselves to enhancing the durability and performance of these essential components through the use of advanced materials and innovative design techniques. Our commitment to quality and innovation ensures that our air bellows meet the highest standards of performance, providing reliable solutions for a wide range of industrial needs.
Enhancing Durability with Advanced Materials
One of the primary factors influencing the longevity and reliability of air bellows is the choice of materials. By utilizing high-quality elastomers and reinforcing fabrics, we ensure that our air bellows can withstand harsh operating conditions and maintain their performance over extended periods. The selection of these materials is critical, as it directly impacts the durability and effectiveness of the air bellows in various applications.
Elastomer Compounds
Our air bellows are manufactured using a variety of elastomer compounds, each selected for its specific properties. These compounds are chosen based on their ability to withstand different environmental conditions and mechanical stresses:
- Natural Rubber (NR/SBR): Offers excellent universal properties and high dynamic capability, making it suitable for a wide range of applications. This compound provides a good balance of flexibility, strength, and resistance to wear and tear.
- Chlorobutyl (CIIR): Known for its outstanding resistance to acids, this compound is ideal for environments with chemical exposure. Its durability in harsh chemical conditions ensures long-lasting performance.
- Nitrile (NBR): Provides excellent resistance to oils, fuels, ozone, and outdoor conditions. This makes it a preferred choice for applications involving exposure to petroleum-based products and outdoor environments.
- Ethylene Propylene Diene (EPDM): Excels in high-temperature environments and offers superior resistance to ozone and weathering. This compound is particularly effective in applications where high temperatures and exposure to the elements are common.
- Chloroprene (CR): Combines good weathering resistance with moderate oil resistance. It is suitable for applications where both environmental and oil resistance are required.
Reinforcing Fabrics
The reinforcing fabrics used in our air bellows are critical to their structural integrity. These fabrics are embedded between the inner and outer rubber layers, providing additional strength and durability. The combination of these materials results in air bellows that can handle high pressures and dynamic loads without compromising performance. The choice of reinforcing fabric depends on the specific requirements of the application, including load capacity, flexibility, and environmental conditions.
Metallic Parts
The metallic parts of the air bellows can be supplied in different qualities to meet various application needs. The standard in most air springs is electro-galvanized steel, which offers a good balance of cost and performance. However, for applications requiring higher wear resistance and durability, we offer stainless steel options such as AISI-304 and AISI-316L. These materials provide excellent resistance to acids, chemicals, and cleaning agents, ensuring long-lasting performance in harsh environments.
Design Innovations for Improved Performance
In addition to material selection, the design of our air bellows plays a significant role in their durability and effectiveness. We offer several design alternatives to meet the diverse needs of our customers, each tailored to provide optimal performance in specific applications.
Dismountable Design
Our dismountable air bellows feature removable clamping bead rings and top and bottom plates. This design allows for easy maintenance and replacement of components, extending the service life of the air bellows. The ability to disassemble and reassemble the air bellows makes them ideal for applications where regular maintenance is required, reducing downtime and operational costs.
Bead Ring Design
The bead ring design involves assembling the air bellow directly to the machine or using additional plates. This configuration provides a secure and robust connection, ensuring reliable performance in demanding applications. The bead rings can be socket head, threaded, or countersunk type, offering flexibility in installation and compatibility with various equipment.
Crimped Design
For applications requiring a non-dismountable solution, our crimped design mechanically crimps the top and bottom bead plates. This design offers a permanent and durable assembly, ideal for high-pressure environments. The crimped design ensures a tight seal and robust connection, making it suitable for applications where disassembly is not necessary or desired.
Advantages of Advanced Air Bellows
The use of advanced materials and innovative designs in our air bellows provides several key advantages, making them the preferred choice for many industrial applications.
Uniform Isolation Properties
Our air bellows maintain constant natural frequency values, even with changing loads. This uniformity ensures effective vibration isolation across a wide range of operating conditions. The ability to maintain consistent performance under varying loads is crucial for applications where stability and precision are required.
Extended Machinery Life
By effectively isolating vibrations, our air bellows help extend the life cycle of machinery and equipment. This results in reduced maintenance costs and increased operational efficiency. The reduction in vibrations minimizes wear and tear on machinery components, leading to longer service intervals and lower maintenance expenses.
Height Control
The air pressure within our bellows can be regulated to maintain a uniform operating height, even with alternating loads. This feature is particularly beneficial in applications requiring precise height control. The ability to adjust the height ensures optimal performance and stability, regardless of load variations.
Best Isolation Degree in the Market
Our rubber bellow isolators are capable of absorbing more than 99% of unwanted vibrations, providing superior isolation performance compared to traditional solutions. This high level of isolation is essential for applications where minimizing vibrations is critical to the performance and longevity of the equipment.
Effective Noise Reduction
The natural frequency of our rubber air bellows reduces structurally transmitted noise, contributing to a quieter and more comfortable working environment. The reduction in noise levels enhances the overall working conditions, making it more pleasant for operators and reducing the risk of noise-related health issues.
Compact Installation Height
Our air bellows are designed with a low installation height, allowing for compact and space-efficient constructions. The compact design is particularly advantageous in applications where space is limited, enabling the integration of air bellows into tight spaces without compromising performance.
Maintenance-Free Operation
Due to the long-life service of our rubber bellows, operational costs are significantly lower compared to conventional cylinders. This maintenance-free operation is a key benefit for many industrial applications, reducing the need for frequent inspections and replacements.
Applications of Advanced Air Bellows
Our advanced air bellows are used in a variety of applications, each benefiting from the unique properties and advantages they offer. The versatility and reliability of our air bellows make them suitable for a wide range of industrial uses.
Vibration Isolation
In applications where vibration isolation is critical, our air bellows provide unmatched performance. They are used in machinery, vehicles, and equipment to minimize vibrations and enhance operational stability. The ability to effectively isolate vibrations improves the performance and longevity of the equipment, reducing the risk of damage and downtime.
Actuation
Our air bellows serve as effective actuators, replacing traditional pneumatic or hydraulic cylinders. Their flexibility allows for lateral misalignment absorption, reducing the need for precision guides and lowering overall costs. The use of air bellows as actuators provides smooth and uniform movements, eliminating the stick-slip effect commonly associated with conventional cylinders.
Load Isolation
With the ability to isolate loads up to 380 kN per bellow, our air bellows are suitable for heavy-duty applications. Their wide size range and load capacity make them versatile solutions for various industrial needs. The ability to handle high loads ensures reliable performance in demanding applications, such as heavy machinery and industrial equipment.
Environmental Resistance
Our air bellows are designed to withstand harsh environmental conditions, including exposure to chemicals, oils, and extreme temperatures. This durability ensures reliable performance in challenging settings. The use of advanced materials and robust designs makes our air bellows suitable for use in a wide range of environments, from chemical plants to outdoor installations.
Storage and Maintenance
Proper storage and maintenance are crucial for extending the life of air bellows. Rubber bellows should be stored in cool, dark, and dry conditions away from direct sunlight or ozone-producing equipment. Following ISO 2230 guidelines helps in maintaining the quality and performance of the bellows over time. Regular inspections and maintenance ensure that the air bellows continue to perform optimally, reducing the risk of unexpected failures.
Pressure Capabilities
The maximum allowable pressure during operation for standard construction air springs is 8 bar. For applications requiring higher pressure, our four-ply construction air actuators can handle up to 12 bar, achieving greater forces and performance. The ability to operate at higher pressures expands the range of applications for our air bellows, making them suitable for more demanding tasks.
At Tevema, we are committed to advancing the durability and performance of air bellows through the use of advanced materials and innovative designs. Our focus on quality and reliability ensures that our air bellows meet the highest standards of performance, providing effective solutions for a wide range of industrial applications. By continuously improving our products and processes, we strive to meet the evolving needs of our customers and deliver superior value.