Installing air bellows properly in industrial machinery is crucial for achieving optimal performance and longevity. Air bellows, also known as air springs, are widely used in various industrial applications for pneumatic actuation, vibration isolation, and height control. In this guide, we will discuss the essential steps for installing air bellows on industrial machinery, highlighting critical considerations, best practices, and expert recommendations to ensure smooth operation.
Selecting the Right Air Bellow
Choosing the right air bellow is the first step toward successful installation. Air bellows are available in different sizes, configurations, and materials, making it crucial to select the right one based on the requirements of your industrial machinery. Key factors to consider include:
- Load Capacity: Ensure that the air bellow can support the required load without exceeding the recommended working pressure.
- Stroke and Height Requirements: Depending on the application, select an air bellow with the appropriate stroke and operating height.
- Operating Environment: Air bellows are manufactured using different elastomer compounds, such as natural rubber, chlorobutyl, nitrile, and EPDM, each having different resistance properties suited for various temperature ranges and media.
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Installation Space Considerations
Proper installation requires adequate space around the air bellow to ensure smooth operation. It’s crucial to avoid sharp objects or surfaces that may rub against the air bellow and cause wear or damage. When installing air bellows, adhere to these guidelines:
- Clearance: Maintain sufficient clearance to allow the air bellow to expand and contract without any obstructions.
- Mounting Surface: The mounting surface must be sturdy and flat to ensure even load distribution.
- Horizontal and Vertical Stops: Provide horizontal stops for air bellows used as vibration isolators to prevent uncontrolled lateral movement.
The support area should cover at least 65% of the air bellow surface to distribute the load uniformly, thereby reducing the risk of localized stress.
Mounting the Air Bellows
The air bellows can be mounted using either crimped bead plates or bead rings, depending on the application. To install air bellows, follow these steps:
- Attach the Bead Plate: For crimped bead plate types, use the blind nuts or bolt holes available on the upper and lower plates to attach the air bellow to the machinery.
- Bolt Tightening: When tightening bolts, ensure that the tightening torque does not exceed the specifications provided by the manufacturer to prevent damage to the bead plates.
- Alignment: During installation, maintain proper alignment of the air bellow to avoid misalignment during operation, which can cause increased wear and decrease service life.
Pressure and Load Adjustment
The maximum operating pressure for most Tevema air bellows is 8 bar, although higher pressures can be supported by four-ply versions. Proper pressure adjustment is key to achieving optimal performance:
- Pressure Regulation: Ensure that the air pressure remains within the manufacturer’s recommended range during operation.
- Pressure Control for Isolation Applications: For vibration isolation, internal air pressure must be adjusted to maintain the desired natural frequency, typically 1-3 Hz, for effective isolation.
Safety Measures During Installation
Proper safety practices are essential for effective installation and maintenance of air bellows:
- Overpressure Protection: Always install stroke limiters to prevent the air bellow from exceeding its allowable stroke.
- Securing Air Bellows: The air bellows must be properly secured, especially when working on a raised chassis, to avoid overstretching.
- Avoid Pressurizing Without Load: Air bellows should never be pressurized without an adequate load. This ensures that the air pressure is not directed at an unrestrained air spring, which can cause damage or pose safety risks.
Common Mistakes to Avoid
1. Inadequate Load Distribution
One common mistake during installation is improper load distribution. It is vital to use appropriate mounting plates and ensure that the load is evenly distributed across the air bellow.
2. Insufficient Clearance
Another mistake is failing to leave enough clearance for the air bellow to operate without obstruction. Make sure that, at the maximum expansion diameter, there is no risk of rubbing against any surrounding components.
3. Incorrect Bolt Selection
The bolts used must meet the manufacturer’s specifications in terms of length, diameter, and material. Using inappropriate bolts may lead to seal failure or mounting issues.
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Post-Installation Inspection
Once the air bellow is installed, perform a thorough inspection to ensure everything is functioning correctly. Key steps include:
- Check Alignment: Verify the alignment to ensure there are no lateral forces acting on the air bellow.
- Pressure Testing: Slowly increase the air pressure while monitoring for any signs of leakage. Address any leaks before putting the system into full operation.
- Stroke Verification: Verify that the air bellow moves smoothly through its intended stroke range without binding or excessive resistance.
Routine Maintenance
Routine maintenance is essential for keeping air bellows in optimal condition and maximizing their lifespan. Maintenance includes:
- Visual Inspection: Inspect for cracks, abrasions, or any wear signs in the bellows.
- Pressure Check: Regularly check the air pressure and ensure it is within the recommended limits.
- Check End Closures: Ensure that bead plates or bead rings remain securely attached and show no signs of corrosion or wear.
If the air bellow is used for vibration isolation, periodic inspections of horizontal and vertical stops are crucial to maintaining effectiveness.
Conclusion
In summary, air bellows installation for industrial machinery involves selecting the right air bellow, ensuring proper mounting, and following specific installation and safety procedures to achieve maximum performance. By adhering to the guidelines presented in this installation guide, users can avoid common mistakes and ensure that the air bellows deliver effective performance, durability, and minimal maintenance.