Air bellows are essential components in many industrial and construction applications, providing unique benefits in both actuator and vibration isolation systems. At Tevema, we offer a wide variety of air bellows tailored for high performance and reliability, specifically designed to address the diverse needs of modern construction environments. Our air bellows offer unmatched versatility, capable of reducing vibrations, supporting heavy loads, and operating in challenging conditions. Below, we delve into the core applications and advantages of these systems, providing valuable insights into their use in construction and industrial contexts.
The Versatility of Air Bellows in Construction
In construction, air bellows are primarily used as actuators and vibration isolators. These devices serve two main purposes: controlling movements with precision and minimizing structural vibrations. As actuators, they excel in their ability to generate high thrust without the friction typically experienced in other types of actuators. Their almost frictionless nature allows for precise and rapid response, making them particularly useful for lifting mechanisms, such as scissor lifts and table lifts.
On the other hand, air bellows are widely utilized as vibration isolators in industrial construction. Unlike rigid springs, air bellows are highly effective in absorbing and dissipating vibrations, which helps extend the life of machinery and protect sensitive equipment from unwanted disturbances. Their flexible design allows them to adapt to different installation conditions, providing constant isolation efficiency despite changing load conditions.
Enhancing Stability and Safety
One of the significant advantages of air bellows in construction applications is their contribution to equipment stability and safety. Due to their compact starting height and extended range of motion, they offer better adaptability in environments where space is limited. For example, scissor lifts equipped with air bellows are capable of reaching operational heights while maintaining a compact retracted size. This adaptability is particularly valuable for bridge construction, building frameworks, and temporary supports that require reliable movement under heavy loads.
Moreover, air bellows have an inherent side-loading capability that distinguishes them from traditional cylinders. The absence of internal pistons or rods prevents the misalignment issues typically associated with conventional cylinders. This makes air bellows ideal for scenarios involving angular motion, such as controlling tilt mechanisms or adjusting the alignment of structures under varying load conditions.
Benefits of Air Bellows Over Conventional Solutions
While there are other actuation and isolation options available in the market, air bellows provide several critical benefits over alternatives such as hydraulic cylinders or metal coil springs:
Low Maintenance and Long Durability
Air bellows are virtually maintenance-free. Unlike hydraulic systems, which require regular lubrication and have numerous moving parts that can wear down, air bellows lack sliding seals or internal pistons. This results in fewer failure points, ensuring extended operational reliability even in environments exposed to dust or debris.
According to studies conducted by Parker Hannifin and ORIA on their reinforced air bellow products, the absence of internal friction elements extends the lifespan and reduces the need for frequent inspections. This contributes directly to lowering the overall cost of ownership, especially for construction equipment that is subjected to demanding use.
Environmental Resistance
The ability of air bellows to withstand different environmental conditions is critical in construction. At Tevema, we provide air bellows made from a variety of elastomer compounds to suit the environmental requirements of each application. The most common materials include:
- Natural Rubber (NR/SBR): Suitable for general use, with excellent resistance to dynamic stress.
- Chlorobutyl Rubber (CIIR): Ideal for applications requiring acid resistance and capable of operating at temperatures up to +115°C.
- Nitrile Rubber (NBR): Provides resistance to oils, fuels, and outdoor weather conditions.
- EPDM: Known for its resistance to high temperatures and ozone exposure.
The right elastomer compound ensures that air bellows can resist extreme temperatures, exposure to chemicals, and outdoor elements, making them suitable for bridges, elevated highways, and marine constructions.
Air Bellows for Vibration Isolation
Construction often involves equipment that produces vibrations, which can lead to structural fatigue, noise, and discomfort for workers. The use of air bellows as vibration isolators significantly mitigates these issues. Due to their ability to maintain a constant natural frequency, air bellows provide efficient isolation regardless of load changes. ORIA’s 2023 catalog highlights that air bellows can absorb over 99% of unwanted vibrations, providing a stable foundation for sensitive machinery such as cranes and precision alignment systems.
The addition of an auxiliary reservoir to an air bellow system can further enhance its isolation capabilities by increasing the volume and reducing the system’s natural frequency. This is particularly useful in environments such as manufacturing plants, where reducing the transmission of vibrations to the foundation is crucial for machine accuracy and longevity.
Effective Noise Reduction
Noise pollution is another concern in construction settings. Air bellows, due to their construction, help significantly reduce structurally transmitted noise. This is achieved by isolating the equipment from the base structure, thereby cutting off the primary pathways through which noise travels. The spring-rubber isolators used in air bellows are known for their ability to dampen both airborne and structural noise, making them an ideal choice for indoor construction work where noise levels need to be controlled.
Key Applications of Air Bellows in Construction
- Scissor Lifts and Elevators: Offering compact collapsed height and powerful thrust, allowing for smooth vertical movement.
- Bridge Support Systems: Providing temporary support and damping during bridge construction or maintenance.
- Vibration Isolation for Foundations: Protecting foundations of vibration-sensitive machinery, such as industrial presses or alignment tables.
- Height and Level Control Devices: Maintaining precise elevation adjustments for construction lifts and work platforms.
- Impact Absorption for Heavy Equipment: Air bellows are effective in absorbing shocks and preventing damage during operations such as pile driving or heavy equipment movement.
Considerations for Installation and Safety
For optimal performance, the installation guidelines must be followed strictly. The following factors should be considered:
- Pressure Management: Standard air bellows have an operating pressure of 8 bar, while high-strength models can withstand pressures of up to 12 bar. Pressure regulation is critical to prevent over-expansion or collapse during operations.
- Safety Stops: It is essential to include mechanical stops to avoid exceeding the maximum working height of the air bellows. ORIA advises against pressurizing air bellows unless constrained by a suitable load, ensuring the system remains stable.
- Support Area: To ensure uniform load distribution, air bellows must be installed with adequate support. At least 65% of the support area should be utilized for effective load-bearing capacity.
Air bellows provide a versatile and effective solution for many construction applications, delivering benefits such as low maintenance, long operational life, and high isolation efficiency. Their flexibility in installation and performance, combined with the ability to function under varying environmental conditions, makes them an essential component in modern construction projects.
As we continue to innovate at Tevema, our focus remains on delivering air bellow solutions that enhance efficiency, safety, and durability in construction and industrial environments.