Step 1: Determine the Required Force

To calculate the required force, you should know the mass of the load and the acceleration required. If your application is a simple push or pull operation, you may just consider the weight of the load and any potential friction.

Force (F) = Mass (m) * Acceleration (a)

If you're dealing with a lifting operation, don't forget gravity () is acting downward. For simplicity, friction is often ignored, but if it is considerable, you must add that force. That’s why it is recommended to add 25% more force than required since that should account for friction and any other factors, such as pressure drops.

Example: If you have a load of and you want to lift it at an acceleration of , the force required is:

F = m * a = x ( + ) =

F = m * a = x ( + ) =

Step 2: Calculate the Required Cylinder Bore Size

Once you have the force, you can find out the bore size, which is the diameter of the piston inside the cylinder. The relationship between the force and the bore size is dictated by the air pressure in the pneumatic system.

Bore Diameter (D) = √[(4*Force) / (π*Pressure)]

The pressure will be in Pascal () for this calculation since it is a universal unit of measurement, but if your system presents pressure in psi, you can easily convert it to pascal: =

Example: If the force required is and the pressure available is (approximately or ), then the bore size would be:

D = √[ (4 ) / (π ) ] = =

Now, choose a cylinder with a bore size that matches or slightly exceeds the calculated area.

Step 3: Define the Stroke Length

The stroke length is the distance the piston can travel inside the cylinder. This is generally dictated by the application’s unique requirements, so there isn't necessarily an equation for it. If the cylinder needs to move a load a certain distance, then the stroke length needs to be at least that distance.

Example: If the application requires pushing an object , the stroke length should be at least .

Step 4: Select the Rod Diameter

The rod diameter is typically chosen from standard sizes based on the bore and stroke length. Larger rods are more resistant to buckling and are often necessary when the stroke length is long.

Step 5: Calculate the Cylinder Speed

You may want to determine how quickly the cylinder will complete its stroke. Calculate this using the following formula:

Speed = (Flow Rate / Cylinder Area) * 60

Flow Rate should be in liters per minute (LPM) and Cylinder Area in cm² for the equation.

Note: This guide provides general steps. Consult with pneumatic cylinder manufacturers for specific applications.