Quick approximate calculations — force, air consumption, leakage cost, speed. These are NOT precise engineering calculations — in a real system, friction, flow resistance and other factors come into play. Good for quick sizing and budget planning; for critical projects always confirm with our engineer.
How much force a cylinder gives at a given size and pressure. Formula: F = 0.0785 × D² × P (D = bore mm, P = pressure bar) — the standard quick pneumatics formula, mm→m² conversion included.
Example: an Ø80mm cylinder at 6 bar gives ≈3014 N (≈307 kgf) out — enough to safely clamp most light assembly parts. Real force is ~5-10% lower due to seals/friction — this calculator shows the theoretical maximum.
The reverse of tool 1: enter the load and the tool suggests a bore Ø from the standard range. Safety factor: usually 1.5 for horizontal pushing; take ≥2 for vertical lifting and fast motion.
Based on theoretical extend force (F = 0.0785 × D² × P). For vertical lifting, remember load holding without pressure too — you need a blocking valve or a brake.
How much flow is needed for the cylinder to complete its stroke in the desired time — and which valve port / tubing matches. An undersized valve is the most common reason a cylinder moves slower than you want.
Flow is per single stroke (extend) in l/min ANR; suggestions are typical indicative thresholds — the real choice also depends on the valve’s Cv/C value, tube length and flow controls. For speeds above ~500 mm/s ask us for a high-speed setup.
How much free air (at atmospheric pressure, l/min ANR) a cylinder uses per cycle. This figure, NOT the cylinder volume itself, is what you compare to compressor capacity.
How it changes with pressure (same cylinder, same stroke):
Why consumption rises with pressure even though the cylinder size stays the same: at higher pressure the same piece of air is compressed more, so converted back to atmospheric pressure (as the compressor makes it) the number is larger. In practice: lowering the working pressure where less force is enough can noticeably cut the electricity bill.
Compressed air is the most expensive utility in a factory — a constant leak costs all year, 24/7, weekends too. Below is a rough table to estimate a leak size from the audible whistle hole diameter (approximate values at ~6-7 bar).
| Hole Ø | ≈ Leak (l/min) | ≈ Leak (m³/h) |
|---|
The default 0.13 kWh/m³ is a typical mid-size screw-compressor value at ~7 bar — your unit may differ. The table is an indicative guide, not a precise flow measurement (that needs a real blowdown test or a flow meter).
This is only a rough practical estimate, not precise — real speed also depends on valve flow, tube diameter/length, exhaust restriction and load. Good for quick orientation, not final sizing.
Will the cylinder’s built-in air cushioning handle your load at end of stroke? E = ½·m·v². If the energy is too high the cylinder “bangs”, seals and end caps suffer, and you need an external shock absorber or deceleration before the end.
Cushioning capacities are typical indicative values for ISO cylinders — a specific series may differ (check the brand catalogue). If the energy is too high: slow down before the end (flow controls), use an external hydraulic shock absorber, or a larger cylinder.
How big and how many suction pads you need to lift a part. For horizontal lifting (pad pulls perpendicular to the surface) use a safety factor ≥2; for a vertical surface (friction holds the part) — ≥4.
Safety factor already included (2 horizontal, 4 vertical). For porous or rough surfaces (cardboard, wood) take a bigger margin and special pads; for oily sheets — pads with internal ribs. −60 kPa is a typical working vacuum for an ejector.
How many bar are “lost” in the tube between valve and cylinder. The drop rises very steeply when the tube is too thin (∝ 1/d⁵) — often this, not the valve, is the real culprit behind a slow cylinder. Uses the standard empirical formula for a straight tube.
Formula: Δp = 1.6·10³·q¹,⁸⁵·L/(d⁵·p) (q = l/s free air, d = inner Ø mm, p = absolute pressure). For a straight tube — every fitting/elbow adds ~0.5–1 m equivalent length. Inner Øs are typical for PU tubing; PA tubes run slightly larger.
How much torque is needed to rotate a load in a given time. For pneumatic rotary actuators, air compressibility calls for a large safety factor (3–5) — especially if the motion must stop at a precise angle.
Assumes uniform accel/decel (α = 4θ/t²), T = I·α·k. If the load rotates in a vertical plane, add the gravity moment (m·g·r); add friction torque as needed. End positions with impact need external stop absorbers.
Quick conversion between the most common pneumatic units — pressure, flow, force, torque.
If the machine has a short heavy demand (blow-off, press, cycle peak) that the compressor can’t keep up with, a receiver covers the deficit — at the cost of an allowed pressure drop. The tool sizes the receiver so pressure doesn’t fall below your limit during the peak.
Sizing: V = deficit × 1.013 / Δp (isothermal). Rule of thumb for the whole system: receiver ≈ 6–10 l per l/s of compressor FAD. If the peak repeats often, check the compressor can refill the tank between peaks.
An approximate full-cycle (out + back) time and how many cycles per minute you can reach at the available flow. The extra time covers valve response and dwell at the positions.
A rough estimate (full piston area both ways, load ignored) — real time depends on load, flow controls and tube length. Also check in tool 4 that the compressor can feed this cycle rate, and in tool 7 that cushioning can take the speed.
The standard that defines how clean compressed air must be — separate classes for solid particles, moisture and oil. A simplified summary below (see the full standard for exact particle count/size thresholds).
| Class | Dew point (pressure) | Max oil (mg/m³) | Typical use |
|---|---|---|---|
| 1 | ≤ −70 °C | ≤ 0,01 | Electronics, pharma, oil-free process |
| 2 | ≤ −40 °C | ≤ 0,1 | Food, beverage, precision coating |
| 3 | ≤ −20 °C | ≤ 1 | Instrumentation, measuring devices |
| 4 | ≤ +3 °C | ≤ 5 | Spraying, tools, general automation |
| 5 | ≤ +7 °C | — | Cylinders, valves, workshop tools |
| 6 | ≤ +10 °C | — | Simple air tools, blow-off |
The simple part: for most cylinders/valves (the core of our catalogue) class 5-6 is enough — meaning a standard FRL unit with filter+regulator. Class 1-2 (oil-free, very dry) usually needs an extra adsorption dryer and an oil-free compressor — a different, more expensive purchase.
Not sure which class your machine needs? Tell us the application — we’ll help pick the right FRL/dryer/filter combination.
Ask for help with air quality →These calculators are for quick orientation. For a critical project — send us the parameters and we’ll confirm with a real engineering calculation.
To the request form →