Compact pneumatic jacks or compressed air jacks are used in pneumatic systems where the cohesive design of fixed mechanisms is of high importance. The main characteristic of this group of pneumatic cylinders is their minimal dimensions compared to standard series. This is achieved by optimizing the design of all components of the pneumatic cylinder. Special attention is given to reducing the length of the piston guides and rod compared to other series.
In today’s article, we will take a closer look at compact cylinders.
What is an Air Cylinder?
Pneumatic cylinders are devices for the linear movement of the working body of machine tools and other mechanisms. Unlike rotary actuators, which have a relatively complex design, pneumatic jacks consist of a hollow tube inside which a rod moves with the help of compressed air, creating a pulling and pushing effect on mechanisms.
Dampers are used to reduce shock loading at the end of the stroke. With a small impact energy, this role is played by rubber rings.
Compressed air jacks are the most common linear actuators due to their small size. They find applications in a wide range of industries, from food and textiles to woodworking and construction materials.
Based on these preconditions and modern technologies, we produce these types of jacks to be lightweight yet strong, made with a techno-polymeric body that enables achieving compact jacks with a high quality-to-price ratio.
Cylinders with piston diameters ranging from 12 mm to 25 mm are produced according to ISO 6432 standards. Their main feature is a body made of nylon filled with glass (sleeve and cap). The mechanical properties of this material are close to aluminum and its corrosion resistance is several times greater.
This allows them to be used where the environment does not permit the use of aluminum mini air cylinders. In this case, the use of stainless steel fasteners for mounting the compact jack is recommended.
How do Compact Jacks Work?
A compact air jack is a pneumatic motor that allows you to convert the energy of compressed air into the translational movement of the output link. The operating principle of this type of pneumatic cylinder is that compressed air from a compressor or another source reaches the piston chamber of the pneumatic cylinder.
And at that moment, the rod chamber is connected to the atmosphere with the help of a distributor, and the pressure of the compressed air acts on the piston, causing its movement to push against the front cap.
The motion of the rod is a result of the movement of the pneumatic jack. To perform the reverse stroke, compressed air needs to be supplied to the end of the rod, and the piston end must be connected to the atmosphere. Under the action of compressed air pressure, the piston moves and the rod moves.
The direction of the flow of compressed air to the piston and rod chambers as well as their connection to the atmosphere or discharge line is managed using special devices—pneumatic distributors.
What Types of Air Cylinders Are There?
Every quality air cylinder is part of pneumatic systems and acts as actuators that utilize compressed air energy. It is worth noting that there are various types of this equipment.
Types of Compact Pneumatic Jacks
1. Piston:
The principle of operation of this device is that when supplied with compressed air, a piston moves along with the rod, deliberately creating a pulling or pushing motion. In other words, this device converts the energy of compressed air into linear movement of the rod.
2. Diaphragm:
They are used exclusively in the regulation of various types of pipeline connections.
3. Single-acting:
This is not the most complex version of the device mechanism. Motion occurs only in one direction since air is supplied to the piston from only one side. Returning to the opposite position can be done manually or with a special spring. The return stroke of the cylinder is not used as a function, thus the efficiency of such a device is significantly reduced.
4. Double-acting:
Air reaches the cylinder from both sides. It is noteworthy that both the forward and reverse movements of the cylinder are operational, which considerably increases the device’s efficiency. However, one should not forget that the force of the reverse stroke is somewhat less than the forward stroke.
There is a distinct difference between the diameters of the manufactured pneumatic cylinders. Depending on the scale of production, you can select the equipment separately. The most popular options are cylinders with diameters ranging from one hundred to two hundred millimeters.
There is an option to install a special magnetic ring on the piston. This is designed to monitor its position with the help of reed sensors. High-quality installation of cylinders can be performed using connectors. There are fittings for flanges and supports and for shafts (fork, ear, hinge) that vary in their operation.
What are Compact Jacks Used For?
Compact jacks may be smaller, but they can be equally powerful. They can be used for linear actuation and control across a variety of applications, including:
- Manufacturing
- Conveyor Systems
- Food Processing
- Material Handling
- Automated Assembly or Sorting
- Bottling and Canning
- Wire Equipment
- Automobile Assembly
- Custom Machinery and Equipment
- Door and Window Frame Manufacturing
- Material Handling
- Packaging and Printing
- Plastic Molding Machinery
- Robotics
- Semi-Conductor Processing
While some larger pneumatic actuators do not use rods, all compact pneumatic jacks employ piston rods. Single-acting devices generate force in one direction only to extend or retract the piston rod.
The opposite motion can be benign (automatically when air pressure is released) or be activated by a spring. Compact jacks and single-acting jacks are suitable for pressing or clamping workpieces or for activating levers or dampers.
Two-effect air cylinders utilize direct pressure to extend and retract the piston rod. This style is typically used in various applications from bending and clamping to lifting and lowering, feeding, sorting, punching, and shaking.
What is the Major Advantage of Compact Jacks?
Compressed air cylinder products offer clear advantages in terms of design adaptability. These advantages include:
- Lighter weight
- Compatibility with more applications and environments.
- Greater flexibility in equipment design
- Multiple installation options to further support efficient design and maximize performance
- Numerous standard configurations are possible.
- Custom designs offer nearly unlimited capabilities.
- Powerful and reliable performance
- Multi-piston designs can be used to increase thrust.
- Feedback sensors can be utilized for positioning multiple loads.
If space is limited, the configuration is challenging, or equipment movement is small, a standard cylinder may not work. Even if it does, it is unlikely to provide you with maximum efficiency. This leads to reduced productivity and, ultimately, profitability.
The ability to reduce footprint without sacrificing power, efficiency, or control can make all the difference for processors. Compact jacks fit into tight spaces and provide movements that only require a short stroke as the rod slides over a small support surface, making them ideal for light-duty applications.
