Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices which utilize the power of compressed gas

to produce a force in a reciprocating linear motion. Pneumatic cylinders use the stored potential energy of a fluid, in this case compressed air, and convert it into kinetic energy as the air expands in an attempt to reach atmospheric pressure. This air expansion forces a piston to move in the desired direction. The piston is a disc or cylinder, and the piston rod transfers the force it develops to the object to be moved.[1] :85 Engineers prefer to use pneumatics sometime because they are quieter, cleaner, and do not require large amounts or space for fluid storage.

Types
Although pneumatic cylinders will vary in appearance, size and function, they generally fall into one of the specific categories shown below. However there are also numerous other types of pneumatic cylinder available, many of which are designed to fulfill specific and specialized functions.

Single acting cylinder

Single acting cylinders (SAC) use the pressure imparted by compressed air to create a driving force in one direction (usually out), and a spring to return to the "home" position. More often than not, this type of cylinder has limited extension due to the space the compressed spring takes up. Another downside to SACs is that part of the force produced by the cylinder is lost as it tries to push against the spring. Because of those factors, single acting cylinders are recommended for applications that require no more that 100mm of stroke length.[1] :85

Double acting cylinders

Double Acting Cylinders (DAC) use the force of air to move in both extend and retract strokes. They have two ports to allow air in, one for outstroke and one for instroke. Stroke length for this design is not limited, however, the piston rod is more vulnerable to buckling and bending. Addition calculations should be performed as well.[1] :89

Other types
Although SACs and DACs are the most common types of pneumatic cylinder, the following types are not particularly rare [1] :89: Through rod air cylinders: piston rod extends through both sides of the cylinder, allowing for equal forces and speeds on either side.

Cushion end air cylinders: cylinders with regulated air exhaust to avoid impacts between the piston rod and the cylinder end cover.

Rotary air cylinders: actuators that use air to impart a rotary motion. Rodless air cylinders: These have no piston rod. They are actuators that use a mechanical or magnetic coupling to impart force, typically to a table or other body that moves along the length of the cylinder body, but does not extend beyond it.

Tandem air cylinder: two cylinders are assembled in series in order to double the force output. Impact air cylinder: high velocity cylinders with specially designed end covers that withstand the impact of extending or retracting piston rods.

Rodless cylinders
Some rodless types have a slot in the wall of the cylinder. That slot is closed off for much of its length by two flexible metal sealing bands. The inner one prevents air from escaping, while the outer one protects the slot and inner band. The piston is actually a pair of them, part of a comparatively long assembly. They seal to the bore and inner band at both ends of the assembly. Between the individual pistons, however, are camming surfaces that "peel off" the bands as the whole sliding assembly moves toward the sealed volume, and "replace" them as the assembly moves away from the other end. Between the camming surfaces is part of the moving assembly that protrudes through the slot to move the load. Of course, this means that the region where the sealing bands are not in contact is at atmospheric pressure.[3] Another type has cables (or a single cable) extending from both (or one) end[s] of the cylinder. The cables are jacketed in plastic (nylon, in those referred to), which provides a smooth surface that permits sealing the cables where they pass through the ends of the cylinder. Of course, a single cable has to be kept in tension.[4] Still others have magnets inside the cylinder, part of the piston assembly, that pull along magnets outside the cylinder wall. The latter are carried by the actuator that moves the load. The cylinder wall is thin, to ensure that the inner and outer magnets are near each other. Multiple modern high-flux magnet groups transmit force without disengaging or excessive resilience.[5]

Design
Construction
Depending on the job specification, there are multiple forms of body constructions available [1] :91: Tie rod cylinders: The most common cylinder constructions that can be used in many types of loads. Has been proven to be the safest form.

Flanged Type cylinders: Fixed flanges are added to the ends of cylinder, however, this form of construction is more common in hydraulic cylinder construction.

One piece welded cylinders: Ends are welded or crimped to the tube, this form is inexpensive but makes the cylinder non-serviceable.

Threaded end cylinders: Ends are screwed onto the tube body. The reduction of material can weaken the tube and may introduce thread concentricity problems to the system.

Material
Upon job specification, the material may be chosen. Material range from nickel-plated brass to aluminum, and even steel and stainless steel. Depending on the level of loads, humidity, temperature, and stroke lengths specified, the appropriate material may be selected.[6]

Mounts
Depending on the location of the application and machinability, there exist different kinds of mounts for attaching pneumatic cylinders [1] :95: Type of Mount Ends Rod End Cylinder End Plain Plain Threaded Foot Clevis Bracket-single or double Torque or eye Trunnion Flanged Flanged Clevis etc.

Sizes
Air cylinders are available in a variety of sizes and can typically range from a small 2.5 mm air cylinder, which might be used for picking up a small transistor or other electronic component, to 400 mm diameter air cylinders which would impart enough force to lift a car. Some pneumatic cylinders reach 1000 mm in diameter, and are used in place of hydraulic cylinders for special circumstances where leaking hydraulic oil could impose an extreme hazard.

Pressure, radius, area and force relationships

Rod Stresses
Due to the forces acting on the cylinder, the piston rod is the most stressed component and has to be designed to withstand high amounts of bending, tensile and compressive forces. Depending on how long the piston rod is, stresses can be calculated differently. If the rods length is less than 10 times the diameter, then it may be treated as a rigid body which has compressive or tensile forces acting on it. In which case the relationship is:

F = A

Where:

F is the compressive or tensile force A is the cross-sectional area of the piston rod is the stress
However, if the length of the rod exceeds the 10 times the value of the diameter, than the rod needs to be treat and a column and bucking needs to be calculated as well.[1] :92

Instroke and Outstroke

Although the diameter of the piston and the force exerted by a cylinder are related, they are not directly proportional to one another. Additionally, the typical mathematical relationship between the two assumes that the air supply does not become saturated. Due to the effective cross sectional area reduced by the area of the piston rod, the instroke force is less than the outstroke force when both are powered pneumatically and by same supply of compressed gas. The relationship between the force, radius, and pressure can derived from simple distributed load equation [7]:

Fr = PAe
Where:

Fr is the resultant force P is the pressure or distributed load on the surface Ae is the effective cross sectional area the load is acting on Outstroke
Using the distributed load equation provided the Ae can be replaced with area of the piston surface where the pressure is acting on.

Fr = P(r2)
Where:

Fr represents the resultant force r represents the radius of the piston is pi, approximately equal to 3.14159. Instroke
On instroke, the same relationship between force exerted, pressure and effective cross sectional

area applies as discussed above for outstroke. However, since the cross sectional area is less than the piston area the relationship between force, pressure and radius is different. The calculation isn't more complicated though, since the effective cross sectional area is merely that of the piston surface minus the cross sectional area of the piston rod. For instroke, therefore, the relationship between force exerted, pressure, radius of the piston, and radius of the piston rod, is as follows:

Where:

Fr represents the resultant force r1 represents the radius of the piston r2 represents the radius of the piston rod is pi, approximately equal to 3.14159.