KEVOS® MAKEOS · Pneumatics
Cylinder Air Consumption Check (Atmospheric Air per Cycle, Total Demand, Compressor Power)
How much compressed air do these cylinders use at their cycle rate, can my compressor supply it, and what shaft power does that take?
Air demand of double-acting pneumatic cylinders: the swept volume of the extend and return strokes with an allowance for dead volume and hoses, the atmospheric air per cycle at the working pressure, the total demand for the number of cylinders and their cycle rate plus a leakage allowance, and the theoretical and shaft power to compress it (as the compressor power tool), against the delivery of the compressor.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Bore | mm | Cylinder bore. |
| Rod diameter | mm | Rod diameter (the return stroke uses less air). |
| Stroke | mm | Cylinder stroke. |
| Cycles per minute (out and back) | Complete out-and-back cycles per minute of each cylinder. | |
| Number of cylinders | Number of identical cylinders. | |
| Working pressure (gauge) | bar | Working pressure. |
| Dead volume and hoses | % | Extra volume in ports, cushions and hoses as a share of the swept volume. |
| Leakage allowance | % | Allowance for leaks across the system. |
| Compressor | ||
| Compressor delivery (atmospheric air) | m³/min | Air the compressor delivers at this pressure, measured at atmospheric conditions. |
| Compression stages | stages | Number of compression stages. |
| Overall efficiency (adiabatic to shaft) | % | Overall compressor efficiency. |
Method and formulas
- Swept volume per cycle = (π D² ÷ 4 + π (D² − d²) ÷ 4) × stroke × (1 + dead volume).
- Atmospheric air = swept volume × (p + p_atm) ÷ p_atm; demand = free air × cycles × cylinders × (1 + leakage).
- Adiabatic and shaft power for the demand at the working pressure (as the compressor power tool).
- Example: 5.5014 L of atmospheric air per cycle; 253.06 L/min in total takes 1.4719 kW.
Limitations
- Cylinders filled to full pressure every stroke; pressure regulators on the return stroke save air.
- Average demand; short peaks need receiver volume.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Check a compressor before adding a machine
- Estimate the running cost of cylinders
- Compare bore sizes on air use
Who it is for
- Automation engineers
- Maintenance engineers
- Energy managers
What you get
- Atmospheric air per cycle
- Total demand
- Compressor capacity and power
Interpreting the result
- Air use grows with the square of the bore: one size down can save a third of the air.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 3032–3041. Topic reference; no source tables or recommended settings are reproduced.
WORKOS tools are screening and decision-support utilities. Verify important financial, engineering, safety, legal or operational decisions using appropriate professional standards and your organisation’s approved data.
