6/29/22, 2:59 PM Why Air Cylinders Fail (and What’s to be Done About it?

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Why Air Cylinders Fail (and What’s to

be Done About it?)
Ernie Lunski, Parker Hannifin Corporation

Pneumatics is typically the technology of choice for applications such as material handling and small-
parts assembly, but new capabilities – including closed-loop control, precision pneumatic components
and high-speed electronics – have made these systems more competitive with electrical and hydraulic
closed-loop systems. In industrial applications across the board, pneumatic cylinders and
components are gaining wider acceptance as being rugged enough to withstand harsh environments
while providing top performance at a competitive cost.

The majority of cylinders for industrial, heavy-duty applications usually conform to National Fluid
Power Association standards. These standards establish dimensional uniformity, so cylinders from
multiple manufacturers can be interchanged. However, care should be exercised when interchanging
cylinders, because even though a cylinder conforms to NFPA dimensional standards, it may have
proprietary features unavailable from another manufacturer.

Also consider that pneumatic cylinders have evolved into an almost endless array of configurations,
sizes and special designs. This versatility makes more innovative configurations possible, but
sometimes it increases sources of failure.

Looking for trouble in all the right places

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6/29/22, 2:59 PM Why Air Cylinders Fail (and What’s to be Done About it?)

Whatever pneumatic cylinder system is specified for a particular application, the plant engineer can
ensure optimal performance by knowing where to look for problems and observing appropriate
troubleshooting protocols. And while it might seem to be a relatively simple mechanical construct, a
pneumatic cylinder can be a complicated proposition when it comes to troubleshooting through a
myriad of specifications.

New technical developments and increasingly sophisticated equipment refinements mandate a more
focused troubleshooting effort for plant engineers to head off problems that can lead to downtime
and equipment damage or failure. But through a rigorous preventive maintenance and troubleshooting
program and knowing where problems can come from, pneumatic cylinders can be kept running at
optimum performance levels while maintaining maximum functionality.

Pneumatic cylinder failure typically results from five different conditions: side-load mounting,
contamination, lack of lubrication, out-of-sync cycle rates and operation in excess of component
limits.

Side-load mounting
Because the function of a valve is to shift, the critical assessment of its efficiency is not when its
position is stationary, but when it shifts. To ensure maximum operating performance, piston rod side-
load mounting should be avoided because cylinders are specifically designed for push-pull stroke
action. Due to the nature of side-load mounting, in which pivot mounts travel in an arc motion profile,
problems can occur as a result of misalignment, off-center loads, rod deflections, imprecise tie-rod
torque or long stroke action.

Side-load applications do not allow the piston rod to work in-line during the extend-retract motion of
the cylinder. This can result in excessive seal failure, bushing wear or galling of the piston rod. In cases
of catastrophic failure, bending of the piston rod or complete breakage of the rod can occur.

During installation, exercise care to properly align the load to be moved with the cylinder’s center line.
Correct alignment of cylinder piston rod with its mating machine component should also be checked
in both extended and retracted positions to ensure proper operation. Improper alignment will result in
excessive rod gland and/or cylinder bore wear, which shortens cylinder life. Note that a cylinder may
have a side load – even though the rod was in-line when the cylinder was first installed – due to wear
of pivot pins or mounting bolts working loose during use.

A rule of thumb is to select a mounting method that absorbs force on the cylinder’s centerline. If the
piston rod is loaded primarily in compression mode, a better alternative is to select a cap-end
mounting style. On the other hand, if the piston rod is loaded primarily in tension, a head-end mounting
is the preferred best practice. In either case, all cylinder mountings should be checked on a regular
basis.

Rod 'run-out,’ or deflection, is a measurement of the rod’s dynamic motion as it travels back and forth
on its stroke. One method of determining rod deflection is to mount an indicator, run the cylinder full
cycle and take indicator readings. The amount of rod deflection depends wholly on the cylinder’s

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6/29/22, 2:59 PM Why Air Cylinders Fail (and What’s to be Done About it?)

alignment. Several installation options are available to optimize cylinder performance. These include
reducing rod-bearing stress by adding a stop tube, while another option consists of using a rod-
alignment coupler to prevent rod deflection.

Contaminants
Cylinders can be contaminated internally from the air supply or externally from the operating
environment. Types of contamination include solids, water and oil. As an example of the potential
adverse effects of contamination, solids such as particulates, pipe rust and scale and thread sealant
debris can curtail seal life, plug orifices and damage surface finishes.

Solids: Gritty environments can wreak havoc with pneumatic cylinder systems. Once any type of
particulate penetrates a nose seal, it can embed itself in seals and bearings, turning them into virtual
sandpaper. But the potential damage resulting from solids contamination can be significantly reduced
by keeping manufacturers’ port plugs intact and in place until the system is actually fitted with piping.
A second option is to thoroughly clean piping before connecting it to cylinder ports to remove chips,
burrs and debris left over from threading and flaring operations.

When cylinders function in hostile operating environments where excessive heat, chemicals, paint or
weld splatter are present, shields can be installed to prevent piston rod and rod-seal damage.
Additional installation options include using a metallic wiper to remove larger particulates from the rod
or adding a rod boot to ensure further protection. Improving air filtration is another option to enhance
cylinder performance.

Water: Water vapor is present in all compressed air applications, where it collects within components
to block orifice flowthrough, dilute pre-lubrication grease, adulterate airline lubricants, damage barrel
or rod finish and freeze in cold weather. Installation options to reduce the deleterious effects of water
vapor include using stainless-exercised steel rods and fasteners or by employing special coatings or
epoxy paints.

Oils: Another type of pneumatic cylinder contaminant consists of oils resulting from air compressor
lubrication carryover or synthetic oils that are typically incompatible with air-line components. Such
oils can cause seal swelling and orifice plugging. Again, plant engineers have the option of selecting
seals that are compatible with oils used in the application to dramatically reduce the damaging effects
of such contaminants.

Insufficient lubrication
Catastrophic failure can also occur when cylinder seals have insufficient lubrication. High or fast cycle
rates can generate unsustainable shock loads at the end of a stroke when the piston hits the end-cap,
or seals can simply run dry from a lack of lubrication. Heat generated by the system could
compromise component temperature limits. Whatever the reason for cylinder malfunction, steps can
be taken to anticipate and prevent failure.

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6/29/22, 2:59 PM Why Air Cylinders Fail (and What’s to be Done About it?)

Potential solutions to lubrication-related problems include selecting a 'non-lube’ cylinder, adding a

lubricator to the air-prep system or integrating an injection lube system. The specifier could also select
an air-cushion cylinder option, add a shock absorber or lower system pressure via a regulator, if
applicable to the system configuration. A final option in this case would be to add flow control to the
cylinder, if high speed is not a major concern.

When properly selected, installed and maintained, cylinders should be leak-free. The fact is, however,
that one or more performance criteria may not be up to spec and leakage can occur. For example,
environmental conditions such as temperature, moisture content or dry versus lubed service affect the
wear – thus leakage rate – of a dynamic seal valve.

Again, steps can be taken to anticipate and prevent potential problems. For example, if leakage occurs
between the end-cap and barrel, check the tie-rod torque. If the torque is on spec, then the barrel seal
should be replaced. When leakage occurs in the rod bushing area, rod seals should be replaced. Inside
the cylinder, leakage beyond piston seals can cause sluggish movement or settling of the cylinder
under load conditions. This occurs due to leakage of worn piston seals and/or rings. Replacement is
the only solution.

Operating over component limits

Operating a cylinder over pressure, load and/or energy limits can also cause the component’s failure.
When cylinders run at overload capacity, seals are subjected to higher stress and friction rates. Rod
ends bend or break, and actuators can come apart. If the system contains speed control or energy-
absorbing devices, pressure spikes can also occur that are two to three times above normal system
pressures.

Several solutions are available to resolve these mechanical issues. First, the operator should make
sure rod accessories are firmly shouldered against it by threading all the way down or by using
spacers or shims. Alternative solutions include either increasing rod-thread size or using a studded
rod end.

Tailor troubleshooting efforts

As long as the plant engineer, the operator and the maintenance staff know what to look for in terms
of unit design, operation, maintenance and troubleshooting procedures, efficient, reliable and cost-
effective processes can be ensured.

Some key questions come in handy as a reference guide in optimizing pneumatic cylinder
performance. These include:

Am I using fittings that actually add contamination? Rusted fittings connected to the cylinder
can introduce particle contaminates.

Do my filters need changing? Filter changes should be a standard maintenance protocol to

effectively remove particulates.

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6/29/22, 2:59 PM Why Air Cylinders Fail (and What’s to be Done About it?)

Am I using the right tools to install my cylinder properly? Using the wrong tools to install
cylinders can cause damage.

Why do I need to properly torque fasteners? This ensures that tie-rods are installed properly.

Is the product warranty in effect? Maintenance workers should check to see if cylinder faults are
covered by the manufacturer’s warranty.

Additional potential problems can arise from materials used in cylinder construction. For example, a
stainless steel cylinder distinctly differs from a stainless-steel body cylinder. Kinetic energy can also
come into play in performance equations. Miscalculating kinetic energy can literally shatter a cylinder.

Operating pressures constitute another consideration in achieving optimum cylinder performance. If

pilot control pressure is too low, the control line may be too small or the metering choke valve could be
malfunctioning. Knowing what to do, how to do it and when to do it – in accordance with protocols of
best practice procedures – will keep equipment humming at peak performance.

About the author:

Ernie Lunski is product sales manager for Parker Hannifin Corporation’s Automation Group. He has
been with the Parker Hannifin Automation Group for nearly 15 years and has more than 25 years of
experience in the pneumatics market. For more information, visit www.parker.com.

About the Author

Ernie Lunski

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6/29/22, 2:59 PM Why Air Cylinders Fail (and What’s to be Done About it?)

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