Description
Overview
The ControlAir Rolling Diaphragm Air Cylinders are engineered to provide virtually frictionless conversion of pneumatic pressure into precise linear force. Unlike conventional piston cylinders, these cylinders utilize a durable rolling diaphragm seal that eliminates sliding seal friction, resulting in exceptional sensitivity, low hysteresis, and smooth, repeatable motion throughout the stroke. This unique design makes them ideal for applications where accurate force control and responsive movement are critical.
The rolling diaphragm forms a long-lasting seal between the piston and cylinder wall while virtually eliminating friction, blow-by leakage, and the need for lubrication. Fabric-reinforced elastomer diaphragms are manufactured using a precision-controlled process and can be customized for operating temperatures from -75°F to 400°F, making these cylinders suitable for a wide variety of industrial environments.
ControlAir offers a complete family of Rolling Diaphragm Air Cylinders, including standard single-acting models, Ultra Cylinders with linear ball bearings for near-zero friction, double-acting cylinders, compact cylinders, and Mini Mights. Multiple mounting styles, stroke lengths, and custom configurations are available to meet the needs of OEM equipment manufacturers and industrial automation systems.
Key Features
- Virtually frictionless rolling diaphragm seal
- Converts pneumatic pressure into precise linear force
- Super sensitivity for accurate force control
- Low hysteresis for repeatable performance
- No blow-by leakage
- No lubrication required
- Smooth, repeatable linear motion
- Long service life
- Custom diaphragm materials available
- Operating temperatures up to 400°F with custom materials
- Available in single-acting, double-acting, and Ultra Cylinder configurations
- Ultra Cylinders utilize Grade A linear ball bearings for nearly zero friction
- Multiple mounting configurations
- Custom rod, bearing, and spring options available
- Designed and manufactured for demanding industrial applications
Performance Characteristics
The Rolling Diaphragm Air Cylinder family is designed to provide extremely low-friction linear motion for applications requiring precise force control and exceptional responsiveness. Unlike conventional piston cylinders that rely on sliding seals, the rolling diaphragm forms a flexible seal that rolls with piston movement, virtually eliminating seal friction while preventing blow-by leakage. This design produces smoother motion, lower hysteresis, and improved sensitivity over the full stroke.
For applications requiring the absolute minimum friction, ControlAir offers Ultra Cylinders, which combine the rolling diaphragm seal with Grade A linear ball bearings and hardened steel rods. This design produces virtually zero friction and outstanding response to even small pressure changes.
Performance Specifications
- Operating Pressure: Up to 145 psig (10 bar)
- Standard Operating Temperature: -40°F to 225°F (-40°C to 107°C)
- Custom Diaphragm Materials: Available for temperatures from -75°F to 400°F
- Cylinder Styles:
- Single-Acting
- Double-Acting
- Ultra Cylinders with Linear Ball Bearings
- Available Effective Areas: 4, 6, 9, 12, and 16 square inches
- Stroke Options: Short and Long Stroke models
- Mounting Options: Universal, Clevis, Foot Mount, Rod Clevis, and additional mounting accessories
- Force Calculation: Force = Air Pressure × Effective Area − Spring Force
Unlike conventional cylinders, the rolling diaphragm design maintains exceptionally low friction throughout the stroke, allowing precise control of small pressure changes while minimizing wear and extending service life. This makes the cylinders well suited for precision tension control, positioning, force regulation, and other demanding pneumatic applications.
How to Select the Right Configuration
ControlAir Rolling Diaphragm Air Cylinders are available in multiple configurations to accommodate a wide range of force, stroke, mounting, and environmental requirements. When selecting the appropriate cylinder, consider the required force, available mounting space, operating conditions, and application requirements.
Select the cylinder style
Choose the cylinder design that best matches your application:
- Single-Acting Cylinders – Ideal for applications requiring spring return and precise force control.
- Double-Acting Cylinders – Provide pneumatic force in both extension and retraction directions.
- Ultra Cylinders – Incorporate precision linear ball bearings for exceptionally low friction and smooth linear motion.
- Compact Cylinders – Designed for applications where installation space is limited.
- Mini Mights – Compact rolling diaphragm cylinders for light-duty pneumatic applications.
Determine the required force
Cylinder output force is determined by:
Force = Air Pressure × Effective Area − Spring Force
Available effective piston areas include:
- 4 in²
- 6 in²
- 9 in²
- 12 in²
- 16 in²
Larger effective areas generate greater output force at the same supply pressure.
Select the stroke length
Depending on the cylinder family, both short-stroke and long-stroke configurations are available to meet application requirements. Refer to the product catalog for available stroke lengths by model.
Choose the mounting style
A variety of mounting configurations are available, including:
- Universal mounting
- Clevis mounting
- Foot mounting
- Rod clevis
- Additional mounting accessories
These options simplify integration into OEM equipment and industrial automation systems.
Consider environmental requirements
ControlAir offers multiple diaphragm materials to suit operating conditions, including custom materials for applications ranging from -75°F to 400°F. This flexibility allows the cylinders to be used in demanding industrial environments with specialized temperature requirements.
Need help selecting the right cylinder?
Applications
Rolling Diaphragm Air Cylinders are used wherever precise linear force, smooth motion, and low-friction operation are required. Their rolling diaphragm design provides outstanding sensitivity and repeatability, making them ideal for precision pneumatic control applications.
Typical applications include:
- Web tension control
- Dancer roll systems
- Valve actuation
- Valve positioning
- Process control equipment
- Force control systems
- Material handling equipment
- Industrial automation
- Packaging machinery
- Printing and converting equipment
- Pneumatic presses
- Tensioning systems
- Precision positioning equipment
- Laboratory and test equipment
- Semiconductor manufacturing
- Medical equipment
- Impact absorbers
- OEM machinery
- Custom pneumatic assemblies
These representative applications align with the product capabilities described in the catalog, including tension control, valve actuation, accumulators, positioners, and impact absorption.
Models & Configurations
ControlAir offers a complete family of Rolling Diaphragm Air Cylinders to meet a wide range of pneumatic motion and force control requirements. Each cylinder family is designed around the same low-friction rolling diaphragm technology while providing different performance characteristics and mounting options.
Available Cylinder Families
- Single-Acting Rolling Diaphragm Cylinders
- Ultra Rolling Diaphragm Cylinders
- Double-Acting Rolling Diaphragm Cylinders
- Compact Rolling Diaphragm Cylinders
- Mini Might Rolling Diaphragm Cylinders
Standard Features
- Rolling diaphragm seal technology
- Virtually frictionless operation
- No blow-by leakage
- No lubrication required
- Long service life
- Low hysteresis
- High sensitivity
- Smooth, repeatable motion
Available Options
- Multiple effective piston areas
- Short- and long-stroke models
- Multiple mounting styles
- Custom diaphragm materials
- Custom spring rates
- Custom rod configurations
- Special operating temperature materials
- Ultra Cylinder linear ball bearing option
Accessories
- Clevis mounts
- Foot mounts
- Rod clevises
- Universal mounting hardware
- Additional mounting accessories
For complete dimensional information, stroke lengths, mounting dimensions, ordering information, and repair kits, please refer to the Product Catalog.
Technical Resources
- Rolling Diaphragm Air Cylinders Catalog (PDF)
- Installation & Maintenance Instructions
- 3D CAD Models
- Engineers Resource Center
- Find a Distributor
FAQs
What is a rolling diaphragm air cylinder?
A rolling diaphragm air cylinder converts pneumatic pressure into precise linear force using a flexible rolling diaphragm instead of conventional sliding seals. This design provides virtually frictionless operation, exceptional sensitivity, low hysteresis, and long service life.
How does a rolling diaphragm cylinder differ from a standard pneumatic cylinder?
Unlike conventional pneumatic cylinders that rely on sliding piston seals, a rolling diaphragm cylinder uses a flexible diaphragm that rolls with piston movement. This significantly reduces friction, eliminates blow-by leakage, and provides smoother, more repeatable motion with no lubrication required.
What are the advantages of a rolling diaphragm seal?
The rolling diaphragm seal offers several performance benefits, including:
- Virtually frictionless operation
- Super sensitivity
- Low hysteresis
- No blow-by leakage
- No lubrication required
- Long service life
- Smooth, repeatable motion
These characteristics make rolling diaphragm cylinders ideal for precision force and motion control applications.
What cylinder configurations are available?
ControlAir offers several cylinder families to suit different application requirements, including:
- Single-Acting Cylinders
- Double-Acting Cylinders
- Ultra Cylinders with linear ball bearings
- Compact Cylinders
- Mini Mights
Each configuration is designed to provide low-friction pneumatic motion while accommodating different force, stroke, and mounting requirements.
What are Ultra Cylinders?
Ultra Cylinders combine the rolling diaphragm seal with Grade A linear ball bearings and a hardened steel rod to achieve virtually zero friction. They are designed for applications requiring the highest sensitivity and the most precise response to small pressure changes.
What operating pressures are supported?
Standard Rolling Diaphragm Air Cylinders operate with air supply pressures up to 145 psig (10 bar).
What temperature range can these cylinders operate in?
Standard cylinders are designed for operating temperatures from -40°F to 225°F (-40°C to 107°C). Custom diaphragm materials are available for applications requiring temperatures from -75°F to 400°F.
What mounting options are available?
Rolling Diaphragm Air Cylinders are available with multiple mounting configurations, including:
- Universal Mount
- Clevis Bracket Mount
- Foot Mount
- Rod Clevis Mount
Additional mounting accessories are also available to simplify installation into new or existing equipment.
Can these cylinders be customized?
Yes. ControlAir offers a variety of custom options, including diaphragm materials, bearing materials, rod configurations, spring designs, mounting styles, and other modifications to meet specific application requirements.
What applications are Rolling Diaphragm Air Cylinders used in?
These cylinders are commonly used in applications requiring smooth, accurate force and motion control, including:
- Web tension control
- Dancer roll tensioners
- Roll loaders
- Valve actuators
- Accumulators
- Positioners
- Impact absorbers
- Industrial automation equipment
Do Rolling Diaphragm Air Cylinders require lubrication?
No. One of the primary advantages of the rolling diaphragm design is that no lubrication is required, reducing maintenance while providing consistent low-friction performance.
Are replacement parts and repair kits available?
Yes. ControlAir offers repair kits, replacement diaphragms, bearing kits, breather vents, protective bellows, and other accessories to support maintenance and extend cylinder service life.
