Mounting air bellows correctly in vehicle suspensions is crucial for optimal performance, longevity, and safety. We at Tevema, as specialists in air springs, understand the importance of correct installation techniques, ensuring a smooth ride and reducing wear on vehicle components. In this article, we will share our expertise on how to properly install air bellows for vehicle suspensions, covering essential mounting guidelines, pressure considerations, and safety measures.
Understanding the Importance of Proper Mounting
Proper mounting of air bellows in vehicle suspensions is essential for ensuring the stability and comfort of the vehicle, while also enhancing the lifespan of the suspension components. Incorrect installation can lead to problems such as improper ride height, reduced vibration isolation, and potential safety hazards.
Our focus lies on best practices that ensure correct alignment, effective load distribution, and adherence to manufacturer specifications to avoid premature failure or reduced efficiency of air suspension units.
Step-by-Step Mounting Guidelines
1. Preparing the Mounting Area
Before starting the installation, the mounting area should be carefully prepared. This includes:
- Cleaning and Inspecting Surfaces: Ensure that the surfaces where the air bellows will be mounted are clean, free of dust, oil, or rust. This helps to avoid any interference with mounting and prevents air leaks.
- Checking Alignment and Space: Verify the alignment of mounting brackets and that the mounting area provides sufficient clearance for the air bellow at maximum diameter. Avoid sharp edges or protruding parts that may damage the air bellow during operation.
2. Installing Mounting Plates and Bead Rings
For some air bellows, such as those available from Tevema, the mounting may involve bead rings or crimped plates. Follow these steps:
- Secure Mounting Plates: Place the mounting plates over the ends of the air bellow, aligning them correctly.
- Use Appropriate Hardware: Fasten the bead rings using the nuts and bolts provided, and ensure the torque follows the recommended values to avoid loosening during operation.
“Engineering is about doing things precisely. Proper mounting of components such as air bellows is not an art, it is a precise science.” — Henry Petroski
3. Air Inlet Connections
Proper air inlet setup is vital to ensure consistent performance. To do this:
- Select the Correct Inlet Size: Most Tevema air bellows come with standard air inlet sizes, usually ranging from 1/4” NPT to 3/4” NPT depending on the application.
- Ensure Leak-Free Installation: Use Teflon tape or appropriate thread sealant to guarantee that there are no air leaks. The air inlet should be securely fastened to maintain the desired pressure throughout the operation.
4. Pressure Considerations
The maximum operating pressure of the air bellow is typically 8 bar for standard constructions, while four-ply reinforced air bellows can handle up to 12 bar. Follow these guidelines:
- Do Not Exceed the Recommended Pressure: Over-pressurizing can cause deformation or failure. Make sure to follow the manufacturer’s specifications when adjusting the air pressure.
- Avoid Operating at Extreme Heights: Air bellows should not be pressurized unless they are restricted by a suitable load or stop. Ensure safety stops are in place to prevent over-extension or bottoming out.
5. Alignment and Safety Stops
Alignment is a critical part of installation, as misalignment can lead to premature wear or damage.
- Alignment During Installation: Align the air bellows with the suspension components properly. Misalignment of even a few degrees can result in excess force on certain parts, reducing the lifespan of the bellows.
- Installing Safety Stops: Safety stops should be installed to limit the stroke and prevent the air bellows from over-extending or compressing too much during operation. Proper use of flexible horizontal stops can significantly enhance the vibration isolation.
Common Issues to Avoid
1. Overstretching During Installation
One of the most common mistakes when mounting air bellows is overstretching during installation. If the chassis is raised without securing the air suspension units properly, the bellows may exceed their intended ride height, leading to irreparable damage.
2. Incorrect Torque on Mounting Bolts
Using the incorrect torque when fastening bolts can either cause parts to come loose or damage the bellows. Always refer to the provided specifications for the correct torque values.
“A good engineer is not one who knows the answer, but one who knows where to find it.” — Albert Einstein
Types of Air Bellow Constructions
1. Crimped Bead Plates
Crimped bead plates are commonly used for smaller air bellows. They are factory-sealed, allowing for quicker installation and ensuring leak-free operation.
2. Bead Ring Assemblies
Larger air bellows, especially those used for heavier vehicles, may use bead ring assemblies. These are versatile and can be used with internal shafts to guide or even pull loads in certain applications.
Pressure Testing and Final Adjustments
Once installed, it is crucial to conduct pressure testing:
- Leak Test: Pressurize the system to the recommended operating pressure and check for leaks using soapy water around all joints.
- Height Adjustment: Ensure that the ride height matches the specification. Air bellows should operate at a specified height to maintain constant natural frequency, which is key for effective vibration isolation.
The proper mounting of air bellows in vehicle suspensions is vital for ensuring long-lasting performance and maintaining ride quality. By following best practices for alignment, pressure settings, and installation, you can prevent many of the issues that lead to premature failure of air suspension systems.
Whether you’re mounting air bellows in a commercial vehicle or a specialized industrial application, the key is always in the details—correct installation will extend the lifecycle of both the suspension and the vehicle itself.