As specialists in metal engineering and air springs, we at Tevema understand the importance of proper maintenance for optimal performance and long-lasting durability of air bellows. Whether these air bellows are used for actuation, vibration isolation, or any other industrial application, adhering to specific maintenance procedures can help ensure reliable operation and a longer service life. Below, we will cover the best practices for maintaining air bellows, keeping your systems running efficiently.
Importance of Proper Maintenance
Air bellows are designed to handle dynamic loads, absorb vibrations, and offer flexibility in diverse industrial environments. The longevity and efficiency of these components depend significantly on maintaining their structural integrity and performance characteristics. Incorrect use or lack of maintenance can lead to premature wear, air leakage, or complete failure, compromising operational safety and efficiency.
Regular Inspection of Air Bellows
The first step in maintaining air bellows is regular inspection. This involves visually checking for signs of damage, such as cracks, abrasions, or cuts on the rubber. The presence of sharp edges or debris around the installation area can cause excessive wear to the bellow surface. To avoid this, we recommend keeping the installation area clean and ensuring that no foreign materials are in contact with the air bellows during operation.
It is also essential to examine the metallic parts of the air bellows, such as end plates or clamping rings. Corrosion or rusting can weaken these components, leading to leakage or improper operation. For applications requiring exposure to harsh environments, stainless steel or other corrosion-resistant materials are recommended.
Proper Pressure Management
Maintaining the correct operating pressure is critical for air bellow functionality. The standard pressure range for most air bellows is 8 bar, though some models can be designed for higher pressures, up to 12 bar for high-strength versions. Over-pressurizing can lead to ruptures, while under-pressurizing can result in inefficient isolation or actuation. We recommend using a pressure gauge to verify that the working pressure is within the permissible range during every inspection.
When adjusting the pressure, make sure the air bellows are properly secured under load. Pressurizing without a load can cause the bellows to expand uncontrollably, potentially leading to damage. Always follow the manufacturer guidelines for maximum and minimum allowable height when inflating.
Storage and Environmental Considerations
Air bellows are made of highly engineered elastomer compounds, making them sensitive to certain environmental factors. For optimal longevity, it is important to store air bellows in a cool, dry place away from direct sunlight and ozone-producing equipment. Exposure to extreme temperatures or direct sunlight can degrade the rubber, reducing the effectiveness of the air bellow. According to ISO 2230, proper storage can significantly enhance the shelf life of rubber products.
Furthermore, it is advisable to avoid storing the air bellows in a compressed state for extended periods. If they are stored compressed, the elastomer may develop a set, which reduces its effectiveness in applications that require repeated cycles of compression and extension.
Installation Guidelines
The installation of air bellows should be conducted with care, ensuring the bellow is aligned correctly. Misalignment can lead to uneven loading, increasing wear and tear. During installation, ensure that the mounting surfaces are clean and that the mounting bolts are tightened to the specified torque values to avoid any unnecessary strain on the components.
In situations where the air bellows operate in a vibrating environment, using flexible horizontal stops is recommended. These stops help control unwanted movement, which can otherwise increase the amplitude of vibrations and cause structural damage. It is also crucial to maintain the proper spacing to prevent the air bellows from rubbing against nearby surfaces or components.
Use of Auxiliary Reservoirs
Adding an auxiliary reservoir to the air bellow system can improve its performance, especially in applications requiring enhanced vibration isolation. Auxiliary reservoirs increase the volume of the air system, which reduces the natural frequency of the bellows and improves its damping characteristics. To maximize efficiency, these reservoirs should be positioned as close as possible to the air bellow, using wide-diameter pipes to minimize flow resistance.
Material and Temperature Considerations
Different materials are used for air bellows depending on their application requirements. Natural rubber (NR/SBR) is commonly used for its excellent universal properties, offering a temperature range from -40°C to +70°C. For applications involving exposure to oils, fuels, or higher temperatures, materials like nitrile (NBR) or chlorobutyl (CIIR) are preferred.
Ensuring that the material selected matches the operating conditions is crucial for preventing premature wear or chemical degradation. Special attention should be given to the temperature and chemical resistance properties of the bellows, particularly in challenging environments such as chemical plants or high-temperature installations.
Safety Measures
Safety is paramount when dealing with air bellows. It is essential to provide stroke limitations to avoid exceeding the maximum allowable height or bottoming out. When the air bellows operate under fluctuating loads, safety stops should be integrated into the system to prevent overextension.
Never allow the air bellows to operate without the appropriate load or mechanical restriction. Free expansion can lead to catastrophic failure, posing a significant safety risk to personnel and equipment.
Conclusion
Maintaining air bellows involves regular inspections, proper pressure management, suitable installation, and attention to material and environmental factors. At Tevema, we believe that proactive maintenance and adherence to best practices are the keys to maximizing the longevity and performance of air bellows in any application. By following these guidelines, you can ensure that your air bellows operate safely and efficiently, providing reliable service for years to come.