Air Cylinder Sizes Mastery: Beginner’s Guide

When it comes to selecting the right air cylinder for your application, the size of the cylinder plays a crucial role. Choosing the correct size ensures optimal performance, efficiency, and safety. In this guide, we will walk through everything you need to know about air cylinder sizes, the key factors to consider, and tips for selecting the best fit for your needs.

What Are Air Cylinder Sizes and Why Do They Matter?

Air cylinder sizes are the actual measurements of the cylinder, especially the bore size, which is the internal diameter of the cylinder and the stroke length, which is the movement of the piston rod. These sizes are important because they define the amount of force that air cylinders can produce and the range of movement of the load. When you are using compressed air to produce linear motion, these sizes are critical in determining the efficiency of the machine or the failure of the mechanism.

An appropriately sized pneumatic cylinder guarantees that the necessary force is applied with little contact between the cylinder and other parts. If the air cylinder size is small, it may not be able to exert enough force and this will result in low performance. On the other hand, if the size is chosen to be large, it is not very efficient as it wastes air pressure, piping, and energy. It may also create dynamic friction where it is not needed or increase the need for lubrication at some places.

Since there are so many sizes of air cylinders to choose from, it is important to understand the fundamentals of sizing, no matter if you are working with stainless steel round body cylinders, rodless cylinders, or other types that benefit from stable lubrication (lube). The right bore diameter and stroke length can affect parameters such as actuation speed, acceleration, and the system’s performance. Well, yes—it does matter quite a lot.

Key Factors to Consider When Determining Air Cylinder Sizes

When determining the appropriate air cylinder size, there are several factors you’ll want to weigh carefully. These elements will not only influence the size but also the overall design and efficiency of your system.

Force Requirements

• The force an air cylinder develops is a function of the bore diameter and the air pressure available. To find the force, one has to know the force required to move the load, which usually includes the force of the piston rod and any other force that may be in the way, such as friction or a shock absorber. The determination of the force needed will help you decide whether to go for a larger or a smaller bore.

Stroke Length

• Stroke length is defined as the distance that the piston can travel in one cycle of operation. This factor is especially important when your project requires long or variable strokes. Most pneumatic cylinders come with a feature of adjustable stroke length to fit the application requirements.

Operating Pressure

• The pressure of your compressed air system, normally expressed in psi, will determine the force that is exerted by the cylinder. Low pressure systems may need larger cylinders to make up for low pressure while high pressure systems can use small cylinders.

Space Constraints

• If your system has spatial constraints, then this should be considered when choosing an air cylinder. For instance, the use of the rodless cylinders is appropriate in situations where the system has to be compact in order to fit in a certain area.

Material and Environment

• Think about the conditions in which the equipment is used and the material of the air cylinder. In corrosive or high moisture areas, stainless steel cylinders are used because of their high strength and resistance to corrosion.

Understanding Bore Size and Stroke Length in Air Cylinders

When talking about air cylinder sizes, two critical measurements dominate: the bore size and the stroke length. Let’s break them down:

Bore Size: The bore size is defined as the internal diameter of the air cylinder. This dimension has a direct impact on the amount of force that the cylinder is capable of producing. The more the bore size, the more force that can be applied by the cylinder in question. For example, a cylinder with a large bore size is suitable for use when your application requires more force to push large loads. However, larger bore sizes may also increase friction and hence need more lubrication than the smaller ones.

Stroke Length: Stroke length is the distance through which the piston rod moves during the operation of the machine. This value is important when accurate control of motion is needed. Longer stroke lengths are required for applications where the linear motion is long while shorter strokes are adequate for short applications.

Knowledge of the relationship between these two factors assists in predicting the behavior of the cylinder under various circumstances. If you need quick response and high acceleration, it is better to use a cylinder with a small diameter and short piston stroke. On the other hand, for heavy duty operations, you may decide to go for a larger bore and longer stroke.

How to Calculate the Correct Air Cylinder Sizes for Your Project

Selecting the right size of air cylinder requires a lot of calculations based on the project that you are working on. Start by determining the force needed to move the load, which can be calculated using the formula: Force = Pressure × Area, where the area is the piston head area calculated by the bore diameter.

Second, compensate for the operating pressure by choosing the bore size according to the available pressure in psi. It is important to note that higher operating pressure means that the same force can be achieved with a smaller bore size.

Last but not the least, the stroke length which is the distance that the piston rod has to move in order to complete one cycle will help in deciding the length of the cylinder. This is a basic approach and as such, it is important to note that some projects may require other factors such as shock absorbers or lubrication systems which affect calculations.

Introduction to Four Common Types of Pneumatic Cylinders

There are several types of pneumatic cylinders to choose from, each offering specific benefits depending on the application. Let’s explore four common types:

CDG Cylinders

Description

• The overall structure of the cylinder is compact, excellent quality, strong thrust and pull, and durable. The product adopts hard oxidized aluminum alloy cylinder body, chrome-plated piston rod, high-quality seals and O-rings, thickened end caps. Various kinds of accessories can be added to adapt to various complex installation environments.

Specifications:

• MODELS: CDG1BN
• BORE: 20、25、32、40、50、63、80、100mm
• STROKE: 25-500+mm

product size chart

DSNU Cylinders

Description

• The overall structure of the cylinder is compact and the overall connection is tight, wear-resistant, leak-proof, smooth and impact-resistant. The product adopts high-quality stainless steel cylinder body, chrome-plated piston rod, imported sealing ring, impact resistance thickened base. Various accessories can be added to adapt to various complex installation environments.

Specifications:

• MODELS: DSNU
• BORE: 10、12、16、20、25、32、40mm
• STROKE:25-500+mm

Product Size Chart

NDC Cylinders

Description

• The overall structure of the cylinder is compact, excellent quality, strong push and pull force, durable. The product adopts hard oxidized aluminum alloy cylinder body, chrome-plated piston rod, high-quality seals, and thickened end caps. Various accessories can be added to adapt to various complex installation environments.

Specifications:

• MODELS: NDC
• BORE: 32、40、63、80、100、125mm
• STROKE: 25-1000+mm

Product Size Chart

SC Cylinders

Description

• The overall structure of the cylinder is compact, excellent quality, strong thrust and pull, and durable. The product adopts hard oxidized aluminum alloy cylinder body, chrome-plated piston rod, high-quality seals and O-rings, thickened end caps. Various kinds of accessories can be added to adapt to various complex installation environments.

Specifications:

• MODELS: SC
• BORE: 32、40、50、63、80、100、125、160、200mm
• STROKE: 25-1000+mm

Product Size Chart

Each of these air cylinders can be further customized to suit your specific application needs, from materials like stainless steel to different types of lubrication and valve systems.

Common Applications and Recommended Air Cylinder Sizes

Air cylinder sizes vary depending on the application, as different industries have specific needs for force, motion, and precision. Here’s a quick look at some common applications and the recommended air cylinder sizes for each:

Automation Systems:

• In industrial automation, where accuracy and speed are paramount, smaller bores with variable stroke lengths are normally employed. Pneumatic cylinders with compact designs such as round body cylinders are common in automation due to their small size and high speed cycling for repetitive operations. These systems generally work at low to medium operating pressures because of the weight of the load and the speed needed.

Material Handling:

• Material handling applications may demand more force to lift or transport loads as compared to other applications. This means that the bore diameters must be larger and the stroke lengths longer to accommodate the needed motion. In this regard, double-acting cylinders are often employed to guarantee that the load is shifted in both directions with linear movement.

Packaging Machinery:

• In the packaging industry, accuracy is very important. Faster responding air cylinders of smaller size are used in many cases. These systems prefer stainless steel cylinders due to their ability to withstand wear and tear, especially when high speed performance and low dynamic friction is required.

Transportation:

• In the case of braking and suspension systems in transportation like buses or trucks, air cylinders are required to exert a lot of force. It is advisable to use rodless cylinders in cases where space is limited but force requirements are high.

Recommended Sizes

For light applications like automation and packaging, smaller bore diameters (ranging from 1 to 2 inches) paired with short stroke lengths (under 10 inches) are common in NFPA specifications. In contrast, material handling and transportation may require larger bore sizes of 4 inches or more, with stroke lengths extending beyond 20 inches for heavier tasks.

Expert Tips for Selecting the Best Air Cylinder Sizes for Efficiency

Choosing the best air cylinder sizes for efficiency doesn’t have to be complicated. Here are some tips to ensure you make the right decision:

Always prioritize force over size by ensuring that the cylinder’s force output is always prioritized over the size of the cylinder because a cylinder that may fit perfectly but does not meet the force requirement will not work as expected. Friction can be addressed by selecting cylinders with low friction seals or by increasing lubrication to reduce wear and guarantee smooth operation when dynamic friction is an issue. Focus on bore size, which is the key to the actuation force your system can generate, and make sure that it is compatible with the air pressure and load weight; however, a larger bore means more power and more air consumption. Select the right cylinder for the application by using rodless cylinders for precision and flexibility in tight areas or using stainless steel cylinders for their ruggedness in corrosive areas. Verify PSI compatibility to make sure the cylinder’s operating pressure matches your system’s air supply; a lower psi may need a larger bore to produce the force needed.

By following these tips, you can ensure your pneumatic cylinder and air compressor are sized correctly for maximum efficiency and longevity in your specific application. Whether you’re selecting a cylinder for an automation system, a material handling project, or a transportation solution, getting the air cylinder sizes right is crucial for smooth, trouble-free operation.

Efficient and Durable Air Cylinders by Hebai-Omch

Hebai-Omch’s pneumatic cylinders are ideal for improving the performance of automation systems in different industries. Hebai-Omch has been in the pneumatic products manufacturing business for almost 40 years and offers high quality air cylinders that are efficient for various industries. These cylinders have components that are machined to fine tolerances, which makes them very durable, easy to operate and perform well in applications that require high levels of automation.

The flexibility and energy conservation of Hebai-Omch air cylinders are some of the benefits. These cylinders can provide linear and rotary motion and are ideal for various automated applications. They effectively translate stored compressed air into mechanical energy, while using minimal energy and hence incurring low operating expenses. These cylinders are small in size, which makes them suitable to be used in areas where space is limited, but they are very effective and of high quality.

Hebai-Omch pneumatic cylinders are easy to control and have a short response time, making them ideal for use in applications that require precise and fast movements in automated processes. They are also very versatile and can easily be integrated with other accessories and automation systems for use in existing systems. Hebai-Omch has been in business for 37 years and has 86 branches all over the world and is well known for manufacturing more than 20 million high quality products in the industrial automation industry.