Norgren eBook

Selecting Pneumatic Cylinders

for OEM Applications

Selecting Pneumatic Cylinders

for OEM Applications
By Sheila Campbell, Product Manager, Actuators

Cylinders today have evolved into an almost

endless array of variations, alternate configurations,
sizes, and special designs. This variety makes more
innovative equipment designs possible, but presents
a challenge to designers to specify the best cylinder
for an application. This eBook presents an overview
of what engineers need to know in choosing the most
efficient standard — or custom — pneumatic cylin-
ders for their applications.

Consider the application

Selecting the right cylinder begins with understanding
the application. Designers need to start by answering
some very basic questions.
• What has to be accomplished? What is the
desired end result of the operation?
• What work will the cylinder perform? Will it
move or lift an object? Open or close a valve?

E
very day pneumatic cylinders are used in • What is the load? How powerful will the
industry to generate force and provide linear cylinder need to be?
motion on a vast variety of OEM equipment. • How far must it move?
They have the capability of moving product directly or
• What is the required cycle time? How quickly
indirectly, by moving components within the machine
must the cylinder stroke and recover?
acting on the product. They do this by pushing or
pulling, lifting or lowering, rotating or just clamping • How will the motion be stopped?
the necessary components. • In what environment will the cylinder
Pneumatic cylinders are simple, cost-effective, operate? Will it be exposed to extreme
easy-to-install devices. They can produce high force temperatures or caustic materials?
and a broad range of velocities. Their motion can
be stalled without causing internal damage. Varying
cylinder materials tolerate adverse conditions such
as high humidity, dry and dusty environments, and
repetitive washdown with high-pressure hoses. That
said, there are a number of investigations that must
be made to select the specific cylinder that can assure
long-term success of each application, as well as the
proper overall function of the machinery on which
they are installed.

Our policy is one of continued research and development. We therefore reserve the right to amend,
9/12 without notice, the specifications given in this document.
© Norgren, Inc. 2012
 Selecting Pneumatic Cylinders

Cylinder types
The original industrial cylinder, still in use today,
Figure A, consisted of a tube or barrel — the cylinder
— closed by sealed end pieces to form the envelope.
Inside was a sealed piston. A rod, attached to the
piston, extended through a sealed opening in one
of the ends. The load was connected to or contacted
by the piston rod and the cylinder was mounted so
it could not move. A port at one end of the cylinder
FIGURE A
allowed compressed air to act on one side of the
piston, causing it (and the piston rod) to move. A
port in the other end of the cylinder allowed air from
the opposite side of the piston to escape — usually
FIGURE B to atmosphere. When the roles of the two ports were
reversed, the piston and rod stroked in the opposite
direction.
The most common pneumatic cylinder is still the
rod style pictured in Figure A. As the name implies,
it usually has a rod protruding from one or both ends.
Other models have multiple rods passing through the
same end to prevent piston rotation. Rod-style cylinders
function in two ways, double-acting and single-acting,
both of which come in a variety of types, including
repairable, disposable, compact, guided or bellows
cylinders. There also are rodless pneumatic cylinders.

Double-acting cylinders (Figure B) use

compressed air to power both the extension and
retraction strokes, moving the cylinder back and forth.
This arrangement makes them ideal for pushing and
pulling loads within the same application. Superior
speed control is possible with double-acting cylinders,
achieved by controlling the rate at which air exhausts.

FIGURE C Single-acting cylinders (Figure C) accept

compressed air on only one side of the piston. The
volume on the other side of the piston is vented to
atmosphere. Depending on whether it is routed to the
cap end or rod end, the compressed air may extend
or retract the piston rod. The most common type of
single-acting cylinder is pressure-extended; then an
internal spring powers the return stroke after pressure
is exhausted. In other designs, gravity or an external
spring returns the piston to its original position.

Our policy is one of continued research and development. We therefore reserve the right to amend,
9/12 without notice, the specifications given in this document.
© Norgren, Inc. 2012
 Selecting Norgren Cylinders

Repairable cylinders can be disassembled to replace

seals and other internal components. This procedure
extends the cylinder’s life cycle. These cylinders
are generally robust in design and will be used in
applications requiring heavier-duty components.

Disposable or sealed-for-life cylinders (Figure

D) have end caps mechanically crimped to the tube.
Internal components are pre-lubed before the cylinder is
assembled. While they are less expensive to manufacture,
they cannot be taken apart to attempt repair without FIGURE D
destroying the housing. These cylinders usually are used
in lighter-duty applications and must be replaced as
opposed to repair when they reach the end of their life
cycle.

Compact-style cylinders (Figure E) are designed

to fit into smaller spaces where only a short stroke is
required. They are used in lighter-duty applications
due to their smaller bearing surface for the rod to
ride against. They are mostly found in single-acting
versions, but double-acting styles also are available.

Guided cylinders (Figure F) serve applications

FIGURE E
with significant side loads or that require that the load
be guided, for example, down a conveyor. A dual-rod
cylinder or a guide block may be the solution.

FIGURE F

Our policy is one of continued research and development. We therefore reserve the right to amend,
9/12 without notice, the specifications given in this document.
© Norgren, Inc. 2012
 Selecting Pneumatic Cylinders

With the addition of mechanical components, a

cylinder’s linear motion can be converted to angular
rotation that can exceed 360 degrees. The rack-and-
pinion rotary actuator (Figures G and H) —
with a rack mounted on the rod — is often used in
the process industry to operate quarter-turn valves.
(Vane-type air motors drive other rotary actuators.)
Sizing rotary actuators requires torque information
about the load to be turned.

Bellows (Figure I) are durable, single-acting,

concertina-like actuators with flexible, reinforced
elastomer walls and metal end plates. They extend
FIGURES G & H
when inflated and develop powerful strokes
because of their large diameters. Their cylindrical
configuration allows them to bend in any direction,
making them useful where loads might vary in angle.
Some application cautions: the maximum extension
and compression of the bellows must be limited by
external restraints. Unrestrained extension can blow
off the end plate; exhaust without restraint can let the
load crush the sidewalls.

The rodless cylinder (Figures J and K) has

no rod extending through its end caps. Instead, an
FIGURE I external carriage slides back and forth on the tube’s
surface. The load mounts on this carriage. An internal
piston is mechanically connected to the carriage
through a sealed longitudinal slot in the cylinder
wall. Long sealing strips on the inside and outside
of the cylinder tube prevent loss of air and ingress of
dust. The slot is unsealed only between the lip seals
on the piston as it moves back and forth. Rodless
cylinders are used for long-stroke requirements and
offer high moment loading capabilities for a variety
of applications. This design saves space because the
stroke is contained within the overall envelope of
the cylinder. Most manufacturers offer a variety of
carriage designs. Three of the most common carriage
options are internally guided, externally guided, and
precision roller guided.

FIGURES J & K

Our policy is one of continued research and development. We therefore reserve the right to amend,
9/12 without notice, the specifications given in this document.
© Norgren, Inc. 2012

Features: A basic vocabulary
Cylinder type is one selection criterion. Below are
some other features to consider when deciding which
cylinder to use. Cylinder and feature selection will
depend on the precise application of the cylinder.
Bore size refers to the inside diameter of the
cylinder tube or barrel. This key dimension is directly
related to the force output capabilities of the cylinder.
A discussion of how to determine bore size based on
force required is found on page 7.
Stroke length is the distance between full extension
and full retraction of the piston rod — the distance
from start to finish of its stroke.
Our policy is one of continued research and development. We therefore reserve the right to amend,
9/12 without notice, the specifications given in this document.
© Norgren, Inc. 2012
Selecting Norgren Cylinders
Pressure rating — designated in pounds per square
inch (psi). Most cylinders are designed to work at
pressures below those available from typical plant-air
systems, but some applications may require higher
pressure. The pressure actually supplied to a cylinder
will normally be reduced through a pressure regulator
to a level that will produce the desired thrust.
Piston rod diameter is dictated by bore size and
application requirements.
Port sizes and locations are also dictated by bore
size, but can be adjusted for custom designs.
Envelope dimensions: The National Fluid Power
Association and International Standards Organization
have established standards for many cylinder
dimensions, making it possible to interchange
cylinders from different manufacturers if replacement
is necessary. Of course there also are many models
with unique dimensions — particularly if options have
been added.
Mounting configuration: Mounting configuration
refers to how the cylinder is attached to the adjacent
equipment. The large number of standard mountings
— both rigid and articulated — usually allows the
cylinder to fit into specific movement criteria as called
for by the application. A variety of mounting hardware
also is available.
Cylinder materials: The operating environment is
the major factor that affects material choice. Typical
material options for pneumatic cylinders include
steel, aluminum, stainless steel, and brass. Some
models are constructed of a combination of these
materials.
 Selecting Pneumatic Cylinders

FIGURE L
Additional options
In addition to the standard features, manufacturers
offer a variety of optional features, including
cushions and magnetic pistons for use with external
reed switches for position sensing. Cylinder
manufacturers also use a variety of methods to
seal the openings in the cylinder barrel and end
cover of a cylinder. Designers have the option to
specify alternative seal materials for applications
FIGURE M that operate in extreme high or low ambient
temperatures or are exposed to caustic chemicals.

If the piston makes metal-to-metal contact with

the end covers at the extreme ends of the strokes,
the result will be noise and potential mechanical
damage. Cushions are devices installed in cylinders
to prevent such contact. Some cushion designs
include an adjustment that can change the rate at
which the trapped air escapes (Figure L). This
allows the machine operator to adjust the rate at
which the cylinder is cushioned at the end of stroke.
(Non-cushioned cylinders are suitable for full-stroke
working only at slow speeds that result in gentle
contact at the ends of stroke. To operate non-
cushioned cylinders at faster speeds, external stops
with shock absorbers can be installed. These should
be positioned to prevent internal contact between the
piston and end covers.)

Some cylinders have integral fixed cushions.  This

involves a pre-engineered fixed cushion orifice that
restricts the flow of exhaust air to slow the piston
down at the end of stroke.  This is beneficial because
it prevents the cushion from being altered under
field conditions: the amount of cushioning effect will
not change and is repeatable. 

Magnetic cylinders (Figure M) have a band of

magnetic material around the circumference of the
piston within a nonmagnetic cylinder barrel. The
magnetic field can be imagined as a donut shape
around the barrel. This shape travels with the piston
as the piston rod strokes in and out. By placing reed
switches on the outside of the barrel — one at each
end, for example — signals will be generated each
time the piston rod completes a stroke.

Our policy is one of continued research and development. We therefore reserve the right to amend,
9/12 without notice, the specifications given in this document.
© Norgren, Inc. 2012

Configuring multiple cylinders
Multiple cylinders can be combined to create special
force and/or stroke results. By mounting two or more
cylinders end to end, they can be extended and/or
retracted selectively to move an attached load reliably
to a number of different positions (Figure N). This is
known as a multi-position arrangement.
The tandem (or multi-power) arrangement also
joins two cylinders end to end, but in this case with
a shared central end cover and a common piston rod
(Figure O). The combination then can double the
pull and nearly double the thrust of a single cylinder
of the same bore size. The tandem arrangement is
suitable as an alternative to a larger bore cylinder
when there is plenty of space available for length but
restricted width and height.
FIGURE N
FIGURE O
Our policy is one of continued research and development. We therefore reserve the right to amend,
9/12 without notice, the specifications given in this document.
© Norgren, Inc. 2012
Selecting Norgren Cylinders
Force is important…
As mentioned earlier, understanding the application
is critical to selecting the right cylinder. Knowing what
the cylinder must do allows the designer to calculate
how much force is needed, which, in turn, determines
bore size. In general, for vertical and high friction
applications, the force required is two times the load
to be moved. Besides the force required to accomplish
the task, in some cases additional force to compensate
for friction may need to be calculated.
A designer who knows the force required and
the air pressure available can solve the following
equations to determine the diameters of the cylinder
bore and the piston. A cylinder’s push force on
extension or pull force on retraction is calculated by
multiplying the effective area of the piston by the
working pressure. The effective area for push force is
the full area of the cylinder bore. The effective area for
pull force is the full-bore area reduced by the cross-
sectional area of the piston rod.
The theoretical push force is, F = π (D2/4) P
Where: F is force in pounds
D is cylinder bore in inches
P is pressure in pounds per square inch
The theoretical pull force is, F = π (D2/4 - d2/4) P
Where: F is force in pounds
D is cylinder bore in inches
d is piston rod diameter in inches
P is pressure in pounds per square inch
Calculating the forces of single-acting cylinders
with a spring is more complicated. The spring force
opposing the push or pull will increase as the stroke
progresses. In practice, manufacturers’ catalogs often
list push and pull values for both double-acting and
single-acting cylinders.
When estimating the relative force of cylinders
with different bore sizes, remember that thrust
increases with the square of the diameter. In other
words, if you double the bore, you will quadruple the
thrust.
 Selecting Pneumatic Cylinders

Engineering custom solu- …And so is stroking speed

tions
In today’s competitive environment, many
times turning to a catalog and picking out stan-
dard components are not enough to give OEM
designers the breakthrough performance they
require. Recognizing this need, Norgren, Inc.,
created its Engineering Advantage approach to
custom design, creating solutions “off-the-menu”
and working with customers to identify motion
control requirements within the larger context of
the pneumatic application.
Sometimes the solution involves combin-
ing standard or modified components in a new
configuration. Sometimes the solution involves
inventing something new. Norgren defines this
approach as “custom” because it is designed for
a specific customer’s application. So when does
Engineering Advantage offer the most benefits?
• When an exact solution is not
available in the catalog
• When the required combination of
components doesn’t exist
• When an application requires pressure, and load, it is usually necessary to have
particularly high efficiency
• When complex motion control
is needed
• When equipment design constraints lability results from uni-directional flow regulators
dictate specialized configurations
The company’s vision is to create competi-
tive advantage for its customers. That means the
Norgren engineering staff exploits the full poten-
tial of motion and fluid control technologies for
their customers’ benefit. Norgren’s goals are
improved machine performance, reliability, and
uptime— as well as lower cost of ownership,
including end-user operating costs.
Speed impacts productivity, longevity and controlla-
bility. The stroking speed of a pneumatic cylinder can
be calculated from
s = 28.8 q / A 
Where s is speed in inches per second
q is air flow in standard cubic feet per min-
ute
A is piston area in square inches
Other factors — external to the cylinder — that will
affect speed in an application are:
• port size
• inlet and exhaust flow through the
control valve
• air pressure
• diameter and length of the hoses, and
• the load against which the cylinder is
working.
With any fixed combination of valve, cylinder,
adjustable control over the cylinder speed. Flow
controls at the cylinder ports can provide this control
and tune speed to the application.
For the majority of applications, the best control-
that are installed to restrict flow out of the cylinder and
allow free flow in. The regulator fitted to the rod-end
port controls the extension speed, and the one fitted to
the cap-end port controls the retraction speed.
What about air consumption?
Calculating a cylinder’s air consumption may be need-
ed most often for fast-cycling production equipment.
Obviously, enough supply air must be available to meet
the application’s requirements. There are two parts
to the air consumption of a cylinder. One is the vol-
ume displaced by the piston; the other is the unswept
volume, such as cavities in the end covers, the cylin-
der ports, connecting tubing, and valve cavities. The
unswept part is likely to be a small percentage and will
vary with individual installations.

Our policy is one of continued research and development. We therefore reserve the right to amend,
9/12 without notice, the specifications given in this document.
© Norgren, Inc. 2012

As in many design situations, it’s best to connect
the pneumatic equipment to a system with enough
capacity to supply it with sufficient air during a “worst
case” scenario. Otherwise there can be air starvation
at a critical time and performance will suffer.
A couple of cautions
A very important general design consideration is to
keep the cylinder thrust as close as possible to the cen-
terline of the piston rod and free from misalignment
or side thrust. Cylinders are normally intended to push
and pull without excessive side load. Off-center thrust
or side loads can substantially reduce the service life
expected from the rod bearing and seals. Off-center
thrust and side loading can be caused by improper
mounting, cylinder deflection under load, machine
frame deflection, and rod bending or sagging — as well
as by poor design of the machine.
Sometimes a cylinder’s bearing load can be
reduced with the addition of an optional internal stop
tube. A stop tube is a spacer placed between the
piston and the rod end head. It increases the distance
between the piston bearing and piston rod bearing when
the rod is fully extended. For additional information
about rod diameter and stop tube sizing, click here.
This configuration is also helpful in applications
calling for cylinders with very long strokes. If there is a
compressive axial load applied to the piston rod, care
must be taken to ensure that the system parameters
of length, diameter and load are within the safety
limits to prevent the exposed rod from buckling. In
some instances, the nature of the application and the
mounting style of the cylinder will allow greater stroke
lengths, while in others the safe stroke length should
be less.
Most pneumatic cylinders are assembled with
a coating of grease on the bore of the barrel and the
seals for service with non-lubricated air. If the com-
pressed air supply is clean and dry, the grease will give
the seals a long life without adding oil through an air
Our policy is one of continued research and development. We therefore reserve the right to amend,
9/12 without notice, the specifications given in this document.
© Norgren, Inc. 2012
Selecting Norgren Cylinders
line lubricator. However, contaminated air will gradu-
ally compromise the original grease lubricant and
shorten the life of the seals. A lubricated air supply
will extend the life of the cylinder, but it will also wash
out the original lubrication, so once lubricated air is
introduced, it must always be used, and the lubricator
should be regularly checked and maintained.
Putting it together
Pneumatic cylinders are the workhorses of industry,
moving and positioning products or machine compo-
nents that act on products. Pneumatic cylinders are
simple and versatile components that have evolved
over time to make more innovative equipment designs
possible. They are also part of an increasingly com-
plex mix of products in today’s industrial world. The
development of cylinders with feedback capabilities
and the use of programmable logic controls are just
two examples. While a cylinder’s performance basics
can be calculated, many external factors will affect its
actual performance.
Putting together an actuator package that will
meet the requirements of an OEM application can be
daunting and time-consuming. Collaborating with a
company that has pneumatic control experience plus
a full product line can shorten the time to solution.
Norgren, Inc, with more than 85 years of motion
and fluid control innovation in a range of industries,
understands the design of standard and custom
pneumatic cylinders — inside and out. The company
delivers world-class, innovative products and services
that set its customers apart from their competition. n
Note: Line drawings in figures B, C, H, K, L and M
are the standard National Fluid Power Association
symbols for the depicted components.
 Selecting Pneumatic Cylinders

Examples of Engineering Unit-Air assembly

Advantage solutions
Baghouse Cylinder
Norgren recently worked with a power genera-
tion plant on an air pollution control system.
Air pollution control equipment that uses engi-
neered-fabric tubes, envelopes, or cartridges to
capture, separate, or filter dust is known in the
trade as a “baghouse.”
A power generation plant needed to rou-
tinely close off chambers in its baghouse. The
plant wanted to do this with a pneumatic-cylin-
der package that:
This cylinder/valve combination integrates a
valve and base to operate the cylinder with a
faster
response time.  The space-saving design sim-
plifies installation and maintenance, as well as
reducing air consumption.  This package can be
used in various industrial applications including
packaging, material handling, printing, paper con-
Unit-Air assembly

verting and more.

Position feedback cylinder
Pneumatic cylinder completely integrated with
Baghouse Cylinder LVDT transducer (internal or external) or LRT
linear potentiometer provides continuous indica-
• provided immediate, repeatable response tion of piston position. It can be used on sorting
• could be adapted to each application at systems, conveyors, and diverters. The unit is
the facility, and manufactured to accept multiple brands of feed-

• integrated all the required pneumatic

and electronic components.

Norgren combined a standard NFPA-

interchangeable cylinder with a directional valve,
air filter, pressure regulator, and electrical wiring Position feedback cylinder
with junction box into the baghouse cylinder back devices.
assembly. The unit was factory-assembled and
tested. The customer only needed to run control Reciprocating air motor
wires directly to the terminal block — saving time This cylinder/valve combination has stroke-signal
by eliminating the need to wire up all individual valves that serve as external pilots. It is used to
components. pump media such as lubricants, fiberglass, foams,
A mechanical lockout feature allows the cyl- resins, hot melt glue, liquid polymers, waste
inder to be used to isolate a particular chamber gases, and other liquids. The cylinder’s quick
for system or component maintenance within response time assists dispensing. The self-con-
the baghouse. With the valve and electronics tained package simplifies installation.
mounted directly to the cylinder, response time
is faster and air consumption is reduced. In addi-
tion, the space-saving combination leaves room
for other components in the air pollution control
system.
Other recent examples of collaboration with
customers to take their requirements from con-
cept to production include:
Reciprocating air motor

This article was previously published in Maching Design.

Our policy is one of continued research and development. We therefore reserve the right to amend,
9/12 without notice, the specifications given in this document.
© Norgren, Inc. 2012