PNEUMATIC CYLINDER
What is Pneumatic Cylinder Work?
mechanical devices that generate force through pressurized air.
converts compressed air energy into a reciprocating linear motion.
simple to use and are a cost-efficient solution to move loads linearly.
As air enters one side of the cylinder, the internal pressure increases,
causing the piston to move in a specific direction. The piston rod then
transfers the resulting force to the object being moved.
Pneumatic Cylinder Parts
Pneumatic Cylinder Bore: The pneumatic cylinder bore houses and
protects the internal components. It is closed by two end caps: these are:
1. front-end (cylinder head) front-end cap is located adjacent to where
the piston rod extends.
2. rear-end (cylinder cap). mounted on the opposite side. One or both
caps have ports that introduce pressurized air inside the bore. Seals
with cushioning capability are placed between the bore and the caps to
prevent leakage and high impact during actuation.
Cap-end port
The cap on the backend of the pneumatic cylinder where compressed air can
enter or exit.
Rod-end port
The cap on the rod-end of the pneumatic cylinder where compressed air can
enter or exit.
Piston:
The disc inside the pneumatic cylinder.
Serves as a movable partition that divides the chamber.
Reciprocates back and forth in a straight line.
Functions:
1. Compressed air enters the port of the rear-end cap.
2. Exerts pressure on the piston and extend the rod.
3. Retracts the rod and return to original position.
Size:
-The piston rod is connected and driven by the piston. It is attached to the
machine element or objects to be pushed.
Types of movement caused by the piston:
Positive Movement: The piston moves outward from the cylinder body. This
is often referred to as the extension or outstroke.
Negative Movement: The piston moves inward towards the cylinder body.
This is often referred to as the retraction or instroke.
Chambers in the pneumatic cylinder
Positive Chamber: This chamber is connected to the compressed air
supply. When air is supplied to this chamber, it pushes the piston forward.
Negative Chamber: This chamber is typically open to the atmosphere or
connected to an exhaust port. As the piston moves forward, the air in this
chamber is pushed out.
Pneumatic Cylinder Parts
The main components of a double-acting pneumatic cylinder.
1. Cap-end port (A): The cap on the backend of the pneumatic cylinder
where compressed air can enter or exit.
2. Tie rod (B): Tie rods are long rods that hold the pneumatic cylinder
together. They run the length of the pneumatic cylinder and connect
the cap and rod-end heads together.
3. Rod-end port (C): The cap on the rod-end of the pneumatic cylinder
where compressed air can enter or exit.
4. Piston (D): A disc shaped element that moves inside the cylinder. It
moves in response to changes in air pressure and connects to the
piston rod.
5. Barrel (E): The cylindrical body that contains the piston.
6. Piston rod (F): The piston rod connects to the piston and moves with
it to create linear motion. The end of the piston rod is typically
attached to an attachment or the load.
Pneumatic Cylinder Parts
Piston Cushioning:
The piston cushioning lowers the speed of the piston and rod assembly
before it reaches the end cap.
It helps to reduce impact, noise, and vibration at the end of every stroke and
enables the piston to move at faster velocities.
Types of Piston Cushioning in Pneumatic Cylinders
I. Mechanical Cushioning:
Internal Cushioning:
1. Built-in damping elements (e.g., oil-filled chambers or rubber
buffers) within the cylinder body.
2. Provides gradual deceleration as the piston approaches the end of
the stroke.
3. Suitable for applications requiring moderate cushioning.
External Cushioning:
1. External devices (e.g., shock absorbers or pneumatic cushions)
attached to the end of the cylinder.
2. Offers more flexibility and customization options.
3. Ideal for applications demanding higher levels of cushioning or specific
deceleration profiles.
II. Electronic Cushioning:
1. Uses sensors and control systems to monitor the piston's position
and adjust the air pressure to achieve a desired deceleration rate.
2. Provides precise control and can be adapted to various operating
conditions.
3. Suitable for applications requiring highly accurate and repeatable
cushioning.
Piston Static Seal: The piston static seal ensures an airtight sealing
between the piston and the rod.
Piston Seal: A piston seal ensures an airtight sealing between the
piston and the chamber. It prevents air from leaking to the other side
of the chamber.
Piston Guide Rings: Piston guide rings prevent direct metallic contact
between the piston and the cylindrical chamber during sliding motion.
They absorb radial forces acting in the cylinder. They are mounted in
the piston and made of chemical resistant, low friction, and self-
lubricating plastics such as PTFE and polyamide.
Polytetrafluoroethylene (PTFE) is a fluoropolymer and is commonly
known by its trade name, Teflon Being hydrophobic, non-wetting, high
density and resistant to high temperatures, incredibly versatile material best-
known for its non-stick properties.
Sensors: are used to detect the linear position of the piston inside the
cylinder. They are important for positioning applications. Reed switches and
Hall-effect sensors are the commonly used pneumatic cylinder sensors.
Common Types of Pneumatic Cylinder Sensors:
1. Reed Switches: Principle: Reed switches utilize a magnetic field to
operate. A small magnet is attached to the piston rod. As the piston
moves, the magnet interacts with reed contacts inside a sealed glass
tube. This interaction causes the contacts to open or close, generating
a signal.
Advantages: Simple design, reliable, and relatively inexpensive.
Disadvantages: Limited accuracy and susceptibility to external magnetic
interference.
Hall-Effect Sensors:
2. Principle: Hall-effect sensors measure the voltage generated when a
current-carrying conductor is placed in a magnetic field. A magnet is
attached to the piston rod, and as it moves, it interacts with the
sensor's magnetic field. This interaction produces a voltage
proportional to the position of the piston.
Advantages: High accuracy, excellent repeatability, and immunity to
external magnetic interference.
Disadvantages: Can be more expensive than reed switches.
Tie Rods:
- Tie rods are the threaded steel rods that hold the end caps to the
pneumatic cylinder bore.
- A static seal is present between the end cap and bore interface.
- The tie rods run around the length of the cylinder. A pneumatic cylinder
can have 4-20 tie rods depending on the size and force it produces,
which makes the cylinder bulkier. The tie rods also protect the cylinder
from possible impact and shock.
What are the different types of pneumatic cylinders?
Double-acting cylinders
Use compressed air on both sides of the piston.
The piston and rod assembly moves toward the side with less internal
pressure, enabling extension and retraction.
Extension force is greater than retraction force due to a larger surface
area on the piston side.
Retraction speed is faster than extension speed because of reduced
effective volume on the rod side.
Suitable for high-speed, high-force applications like gate and valve
operations.
Offers consistent output, handles longer strokes, and requires robust
cushioning.
Consumes more compressed air and is more costly.
Piston position becomes indeterminate during pressure or power loss.
Single-acting pneumatic cylinders
Use a spring to assist in piston retraction.
Compressed air enters one side of the chamber, causing linear
extension of the piston and rod assembly.
The spring returns the piston and rod assembly to its original position
after extension.
Air is vented through a port after the piston reaches its maximum
thrust.
In case of pressure loss or power interruption, the piston returns to its
base position.
Single-acting cylinders classifications
1. push-type cylinder: pressurized air extends the piston rod outward
from the cylinder.
2. pull-type cylinder: the pressurized air retracts the piston rod into the
cylinder.
Rodless pneumatic cylinders
loads via a piston propelled by compressed air.
The piston travels linearly and is linked to a carrier that supports the
load.
Strokes are proportional to cylinder dimensions and can be achieved at
higher speeds.
Ideal for compact spaces; end cushioning is needed to avoid harsh
impacts.
Rodless pneumatic cylinders are available in three distinct types:
Band Cylinders
Band cylinders feature a carrier linked to the piston through two
sealing bands that run parallel to the direction of the stroke.
These bands can be constructed from materials like plastic or stainless
steel.
The outer band is positioned on the exterior of the cylinder bore slot,
attached to the carrier, while the inner band is situated inside the
cylinder bore, connected to the piston.
As the carrier moves, it causes the sealing band in the direction of the
stroke to open, while the band behind the carrier remains closed.
Cable Cylinders
In cable cylinders, a cable connects the piston to the carrier, with the
cable passing through pulleys located on each end cap.
As the piston moves, it pushes the cable, which in turn shifts the
carrier.
Cable cylinders are cost-effective and feature a straightforward design,
but they can suffer from issues such as cable wear, which may lead to
imprecise carrier positioning and potential leakage.
Magnetically Coupled Cylinder
Magnetically coupled cylinders operate without a direct mechanical link
between the piston and the carrier.
Instead, a powerful magnetic field transfers motion from the piston to
the carrier, ensuring a sealed cylinder and preventing air leakage.
However, there is a risk that the carrier may become detached from
the magnetic coupling and can be sensitive to moment loads.
