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Differential pressure sensing detects cylinder end-of-stroke positions by monitoring the pressure difference between chamber A and chamber B. When the piston reaches either end, pressure in the active chamber spikes while the exhaust chamber drops to near-atmospheric, creating a distinctive pressure signature that reliably indicates position without any physical switches, magnets, or sensors mounted on the cylinder body.

Dual-loop control strategies use two nested feedback loops to synchronize multiple pneumatic cylinders: an inner velocity loop that controls individual cylinder speed through proportional valve modulation, and an outer position loop that compares cylinder positions and adjusts velocity setpoints to minimize synchronization error. This architecture typically achieves ±0.5mm to ±2mm synchronization accuracy across stroke lengths up to 3 meters, compared to ±10-50mm with basic pneumatic systems.

galvanic corrosion occurs when dissimilar metals in your cylinder assembly create an electrochemical reaction in the presence of moisture, leading to accelerated deterioration of critical components.

Dead volume refers to the compressed air trapped in cylinder end caps, ports, and connecting passages that cannot contribute to useful work but must be pressurized and depressurized with each cycle, directly reducing energy efficiency by requiring additional compressed air without generating proportional force output.

Heat generation in high-cycle cylinder seals occurs due to friction between sealing elements and cylinder surfaces, adiabatic compression of trapped air, and hysteresis losses in elastomeric materials, with temperatures potentially reaching 80-120°C that accelerate seal degradation and reduce system reliability.