With the use of traditional cylinders, many industries were facing the challenge of how to move loads smoothly without wasting time or space. However, as the rodless cylinders came to the market, they solved all the problems and made the processes easier and seamless. Basically, rodless cylinders are compact pneumatic cylinders that are specifically designed to get precise results. So, in this blog, you will learn what they actually are, how they work, why they matter, and how they can solve your toughest problems. Well, keep learning!

 

1) What Are Rodless Cylinders?

“Rodless cylinders are a kind of pneumatic actuator that uses compressed air to move the load in a linear motion without using an external piston rod”.

Rodless cylinders are reliable and efficient because they use their internal piston to push or pull the load, so they don’t use any external rod, which saves space.

Their internal piston moves the load over long distances, so they also reduce side loads and bending, which helps extend their life. Due to their flawless performance, you will find them in many machines that need smooth, long-distance motion.

2) Key Advantages of Using Rodless Cylinders

The Rodless cylinders offer several clear benefits over traditional air cylinders. So, let’s now discuss the key advantages of using rodless cylinders, which are:

+ Space saving: One of the biggest advantages of the rodless cylinder pneumatic is space-saving. Since there is no rod that extends out, the entire stroke happens within the length of the cylinder. This makes them perfect for machines where space is tight.

+ Long-stroke applications: They are also ideal for long-stroke applications. A rodless cylinder can move loads across long distances without taking up extra space. Traditional cylinders need space equal to twice their stroke length, but rodless cylinders need a small space. Because of the long stroke applications, rodless cylinders become more compact and efficient.

+ Better load support: Another key advantage is better load support. The moving carriage on a rodless cylinder offers a stable platform. So it reduces side loads and bending issues. On the other hand, traditional cylinders don’t have load support that can damage them over time.

+ Energy efficiency: Energy efficiency is another plus point of rodless cylinders. Unlike the traditional cylinders, they use less compressed air due to less friction and better balance. So, it reduces the operating costs and makes systems more eco-friendly.

+ Maintenance: Rodless cylinders are simpler as they have fewer moving parts. So, there are a few components that have a chance of wearing out. Apart from this, many rodless cylinders are sealed to keep dirt and dust out, this quality makes them more durable.

+ Flexibility: Lastly, they are flexible. You can fix them in many ways and use them in horizontal or vertical positions. So, they can push or pull the loads easily.

3) Working Principles of Rodless Cylinders

Rodless cylinders work using compressed air, just like a regular pneumatic piston cylinder. But the main difference is in how they move the load. Now, let’s talk about the working principle of rodless cylinders.

When air pressure is applied, there is a piston inside the cylinder that moves. Actually, the piston travels inside a sealed tube. Now, the piston is connected to the carriage that moves along the cylinder and moves the load. To make it simple, the load moves in a linear way along with the carriage.

There are two common ways the piston connects to the carriage. One is mechanical coupling, and the other is magnetic coupling.

• In mechanical types, there is a slot along the cylinder. So a sealed band or strip keeps it airtight. As the piston moves, the carriage moves along with it.

• In magnetic types, the powerful magnets are built to connect the piston with the carriage. Therefore, when air moves the piston inside, the magnetic force pulls the carriage along the outside.

Both types work well. Mechanical ones are good for heavy loads, and Magnetic ones are cleaner because they are fully sealed, making them ideal for dusty or wet environments.

Additionally, sensors are often added to track the piston’s position. These sensors also help to control the position of the piston so that it moves with accuracy.

4) Applications in Various Industries

Rodless cylinders are used in many industries because they save space and move loads smoothly. So, this makes them useful in machines where space and speed matter. Now let’s discuss the rodless cylinder’s applications in various industries. Keep reading!

• In the packaging industry

Rodless cylinders help move products along conveyors and are used to open and close flaps, push items into boxes. Their smooth motion is perfect for fast and accurate work.

• In automotive manufacturing

They are used in assembly lines, so they help move parts like doors, panels, and seats into position. Since they can handle long strokes, they are ideal for moving large or bulky parts.

• Electronics and semiconductor plants

Rodless cylinders are used in electronics and semiconductor plants. Magnetic rodless cylinders are sealed, so they prevent dust from entering. It makes them perfect for moving small, sensitive parts without causing contamination.

• In material handling 

Rodless cylinders are used to slide items properly across the work areas. They are often found in sorting machines, palletizers ( an industrial machine that automatically places products in a pre-defined manner on a pallet for shipping, storage, and organisation), and pick-and-place systems.

• Printing and labelling machines

The rodless cylinders are used in printing and labelling machines to move paper or products through the system. Moreover, their smooth, straight motion helps keep everything aligned and accurate.

• In medical equipment

These cylinders support tasks like moving trays or adjusting parts in diagnostic machines. So, their quiet operation and clean design make them suitable for hospital settings.

• In robotics, food processing and textile machines 

Rodless cylinders are also used in robotics, food processing, and textile machines. They are reliable, easy to install, and require little maintenance.

5) Maintenance, Troubleshooting, and Best Practices

Despite rodless cylinders being designed with longevity in mind, they, like all mechanical tools, require regular attention. Having a maintenance plan improves performance and increases the working lifespan.

• Maintenance

Effective maintenance guarantees the proper functionality of the rodless pneumatic cylinder and helps avoid failure.

• Start with cleaning: First of all, it is important to keep the rodless cylinders clean. Because moisture, dirt, and dust can impair its performance. This is especially important for magnetic cylinders because debris may inhibit the strength of the magnetic connection. So, wet wipes are useful for cleaning the cylinder body regularly.

• Check sealing bands:  Visually inspect the mechanical type sealing band to see if it is cracked, worn out, or poorly sealed. If the band is damaged, then it will decrease the efficiency of the cylinder’s functions.

• Carefully check for lubrication: Usually, most rodless cylinders are pre-lubricated. However, with time, they lose their lubrication. So, always check the manufacturer’s guidelines on when and how to reapply the lubricant to avoid damaging the rodless cylinders. If you do not apply lubricant on time, it can lead to poor performance.

• Check tightening and damage: Heard a hissing sound? If yes, then it means there is an air leak. Leakage in air pressure leads to a lowering of pressure in the cylinder, which will make it slow or weaken it. So it is necessary to fix, tighten, or replace the loose fittings and damaged tubing.

• Troubleshooting

In case your cylinder doesn’t seem to be operating effectively, don’t worry. In fact, most issues are simple to identify and fix them well.

? Poor or slow movement of a carriage: You should examine the air pressure. It could be set lower than intended. And, check the blockages in the piston movement.

? Jerking or uneven load motion: Check guide rails and ensure that the load is evenly distributed as well as positioned correctly for optimal alignment. Moreover, it is crucial to avoid side loads that could strain the cylinder.

? Are your sensors giving you faulty readings? Make sure to check alignment. Misalignment of sensors can lead to poor feedback, as a result, we face problems in controlling the cylinder.

•  Best Practices

 To ensure safe and precise operations on rodless cylinders, it is important to perform the following activities on maintenance:

• Prevent internal damage from moisture or particles by using clean, dry and filtered air. The air used should not lead to corrosion, seal wear, or reduced functional performance over time.

• To avoid losing cylinder lifespan, securely fix the cylinder in position, ensuring that it is perfectly aligned with the load to avoid uneven rotation or wear, which will cause misoperation.

• Avoid overloaded bearing surfaces on the carriage, as they impact performance and damage the internal bearings, which leads to premature failure.

• Avoid putting stress on the cylinder by guaranteeing that all components connected to the system are properly aligned. Failure to do this will exert additional forces on the internal piston and the carriage.

• To eliminate system pressure loss, preemptively apply maintenance before costly breakdowns happen.

• Running system pre-emptive maintenance is crucial to avoid unplanned downtime, which is guaranteed by checking for proper sensor workings prior to setup.

This enhances the reliability, longevity and guarantees uninterrupted movement on rodless cylinders.

6) FAQ

1. What are the advantages of using rodless cylinders over traditional cylinders?

Rodless cylinders allow longer stroke lengths to be achieved within a compact body. Additionally, rodless cylinders help reduce side loads, enable smoother motion, and also better control the load. Furthermore, rodless cylinders save space since there is no need for a long external rod.

2. What is a rodless cylinder, and how does it work?

A rodless cylinder is a type of pneumatic actuator that uses an internal piston that is coupled to a carriage that carries the load externally. In a rodless cylinder, compressed air enters the cylinder, which pushes the piston. The piston then pushes the carriage that is located at the side of the cylinder. The load moves in a linear motion.

3. How do I select the right rodless cylinder for my application?

When choosing a rodless cylinder, it is important to look for stroke length, available mounting space, speed, load weight, and the working conditions.

4. What future trends are emerging in rodless cylinder technology?

The advancement of rodless cylinders includes the addition of smart technologies for enhanced sensors, satellite-based IoT systems, and real-time monitoring systems for predictive maintenance. Moreover, the eco-friendly materials are used in the construction of rodless cylinders.

7) Conclusion

With rodless cylinders, moving machine parts becomes easier. Unlike regular cylinders, these rodless cylinders save space, work silently, and require less maintenance. For machinists seeking precision, rodless cylinders make the machines lighter, faster, durable, and reliable. These are ideal for manufacturing industries as they need to perform long movements within confined locations. Rodless cylinders are the best modern-day solution to enhance the performance of machines and prevent other issues.

If you want to expand the capabilities of your equipment with top-of-the-line rodless cylinders, check out the catalogue from Xingchen Pneumatic. We have a range of rodless cylinders that are best for long-stroke applications in the packaging, robotics, and material handling industries. They are extremely useful when it comes to optimising the reduction of operational and maintenance downtime for your systems. You can contact us with a single click here.