When it comes to specialised machinery, one of the key components that can make all the difference is the custom air bellows. We design and manufacture air bellows specifically for machines where conventional springs or pneumatic cylinders fall short. Our extensive experience enables us to create air bellows tailored for various industrial applications—ranging from high-force actuators to vibration isolators, providing bespoke solutions for industries demanding performance and reliability.
Why Custom Air Bellows Matter for Specialised Machinery
Custom air bellows provide unique solutions to challenges where standard off-the-shelf products do not meet the required performance specifications. From the enhanced stroke control to specific load-bearing requirements, these air bellows are designed to deliver optimized functionality.
Specialised machinery often encounters environments and tasks that demand more than just a simple pneumatic cylinder or conventional spring can offer. In these situations, custom solutions, such as air bellows, help reduce maintenance needs, minimize equipment failures, and ultimately enhance productivity.
Performance Benefits
One of the biggest advantages of using custom air bellows is their frictionless movement. Unlike traditional actuators, air bellows lack moving metal parts, allowing for virtually frictionless motion and increased durability. The absence of internal pistons or sliding seals results in reduced maintenance and a longer lifespan. This feature becomes especially critical when dealing with highly specialized machinery, where efficiency, uptime, and maintenance reduction are key concerns.
Custom air bellows also provide high thrust capability, which is especially useful in applications where a significant amount of force is needed over a short stroke. By adjusting the internal pressure and tailoring the bellows’ construction, we can meet various force requirements while still offering the flexibility of multi-directional movement. Moreover, their angular capability of up to 30 degrees allows for a high range of versatility in the application.
“A good engineering solution is to find a simple mechanism for a complex task.” – Henry Petroski
Applications of Custom Air Bellows in Specialised Machinery
Our custom air bellows find applications across a variety of specialized machinery, including:
1. Lifting and Actuation Devices
We manufacture air bellows that serve as efficient lifting actuators for applications such as scissor lifts, hydraulic presses, and platforms. Their compact profile and high force generation make them ideal for scenarios where lifting is required with minimal space.
2. Vibration Isolation
Custom air bellows are particularly effective as vibration isolators. With the ability to reduce vibrations by up to 99%, these bellows provide the best isolation available for specialised machinery. When used in machines that generate significant vibration—such as compressors, conveyors, or industrial presses—air bellows contribute to extended machine life by significantly reducing wear and tear.
3. Positioning and Alignment
Precision positioning in equipment often relies on components that offer smooth, adjustable movement without backlash. Custom air bellows excel at providing fine adjustment capability, making them suitable for machinery that requires exact alignment and smooth positioning, such as those found in production lines or automated robotic systems.
Material and Customization Options
Depending on the requirements, air bellows are manufactured using different elastomer compounds like:
- Natural Rubber (NR/SBR): Standard material with great universal properties, suitable for applications ranging from -40°C to +70°C.
- Chlorobutyl Rubber (CIIR): Known for its outstanding resistance to acids, suitable for higher temperatures, up to +115°C.
- Nitrile Rubber (NBR): Perfect for applications needing resistance to oils, fuels, and ozone, covering a range from -25°C to +110°C.
We provide custom air bellows in configurations from single to triple convoluted designs, giving clients flexibility depending on the application needs—whether for higher stroke lengths or increased load-bearing capabilities. Depending on your specific machinery requirements, we also offer customizations that include four-ply construction for higher pressure ratings, achieving capabilities of up to 12 bar.
Advantages Over Standard Air Springs
Custom air bellows are preferred in specialised machinery due to their distinct benefits over conventional air springs or other mechanical counterparts.
- Minimal Maintenance: Air bellows lack the moving components that are prone to wear and thus require minimal maintenance.
- High Side Load Capacity: Air bellows do not suffer from side loading problems common in pneumatic cylinders. This feature means fewer concerns about rod bending or scoring, which can shorten the lifecycle of machinery.
- Adaptable Height Control: Precise height adjustment with custom air bellows is much simpler, making it an ideal solution for machines that require accurate load adjustment or need to maintain a constant height.
“The secret of success is in perfecting simplicity.” – Buckminster Fuller
Improving Equipment Longevity and Efficiency
Our customized air bellows not only address complex requirements but also extend the overall life cycle of the equipment. By effectively isolating vibrations and reducing structurally transmitted noise, custom air bellows contribute directly to enhanced machinery performance.
Take, for example, equipment used in the food processing industry. Machinery that operates in high-vibration environments often sees frequent failures and high maintenance costs. By integrating custom air bellows, the vibration loads on critical parts are mitigated, reducing downtime and improving the working conditions of the equipment.
In addition, the use of high-grade materials like stainless steel (for fittings and end plates) helps enhance the longevity of air bellows in challenging environments. Whether it’s exposure to chemicals, oils, or extreme temperatures, using the appropriate materials ensures reliable operation.
Key Considerations for Custom Air Bellows Selection
Selecting the appropriate air bellows for specialised machinery involves a detailed understanding of:
- Load Requirements: Understanding the load requirements is crucial for determining the optimal design and pressure levels required.
- Stroke and Installation Height: The installation space, including minimum and maximum height, should be evaluated to avoid over-pressurization or bottoming out.
- Temperature and Environment: Depending on the temperature range and environment—such as whether the bellows will be exposed to chemicals—it is important to choose the appropriate elastomer compound and metallic components.
- Safety and Stop Limits: Proper safety stops must be implemented to prevent exceeding maximum permissible heights during operation, ensuring longevity and consistent performance.
Custom Air Bellows: A Versatile and Robust Solution
The versatility of custom air bellows for specialised machinery cannot be overstated. Their application in a variety of industries—such as automotive, food processing, textile, and mining—highlights their reliability in both actuator and isolator roles. Their angular stroke capability, low maintenance needs, and frictionless performance make them a preferred choice for complex engineering challenges.
If your specialised machinery requires unique performance characteristics that cannot be achieved with standard parts, custom air bellows might be the solution. With decades of expertise, we can design the right product to ensure your machinery operates smoothly and efficiently.
For those looking to enhance the performance of specialised machinery, custom air bellows provide a versatile, reliable, and cost-effective solution. They can offer precise control, excellent vibration isolation, and long-term reliability, making them indispensable in modern industrial applications. Let us help you find the perfect custom air bellows solution for your needs.