How to Ensure the Long Lifespan of Electric Actuators – Practical Tips for Efficient Production Processes

Introduction to electric actuators

Electric actuators are the foundation of modern industrial automation solutions, enabling precise control of linear and rotary motion in many production systems. A linear electric actuator converts the rotary motion of an electric motor into linear motion. Thanks to their reliability, speed, and high precision, they are used across various industries, including automotive, food processing, chemical, and pharmaceutical sectors. Proper selection and operation of electric actuators in industrial automation are crucial for machine efficiency and durability.

What is an electric actuator?

An electric actuator is a device that converts electrical energy into mechanical motion. Used in industrial automation systems, electric actuators are responsible for executing machine movements, which is particularly important in processes requiring high precision and repeatability. They can operate in linear (straight-line) or rotary modes, depending on the application. Unlike a gas actuator, which uses compressed nitrogen to lift and lower objects, electric actuators offer different advantages and applications.

Types of electric actuators

Electric actuators are available in different types, tailored to the specific requirements of industrial applications. The most common types include:

• Linear electric actuators: Designed for linear motion, these actuators are widely used in industrial applications requiring precise straight-line movement control. Due to their robust construction, they can operate in harsh conditions while ensuring reliability and long service life.
• Rotary electric actuators: These actuators are designed for rotary motion. They are used in applications requiring precise control of rotation angles, such as rotary valves or rotating mechanisms.
• Dual-function electric actuators: Combining the features of both linear and rotary actuators, these actuators enable both motion types. They are ideal for applications requiring versatility and flexibility in motion control.

Applications of electric actuators in industrial automation

Electric actuators play a crucial role in various industrial applications, increasing efficiency and effectiveness across many sectors.

• Production process control: Electric actuators are used to precisely control movement in machines and equipment, essential for production processes requiring high accuracy.
• Integration with pneumatic and hydraulic systems: Electric actuators are often used in systems that combine different control technologies, ensuring smooth and efficient production management.
• Automation: In production processes requiring automation, electric actuators allow full automation of various production stages, increasing efficiency and reducing operational costs.

Construction of electric actuators

An electric actuator consists of several key components that ensure its effectiveness:

• Electric motor: Converts electrical energy into mechanical motion, driving the entire system.
• Gear mechanism: Adjusts speed and torque, providing the necessary force for the actuator’s operation.
• Piston: In linear actuators, the piston is responsible for executing straight-line motion, essential in processes requiring precise motion control. Many electric actuators use stainless steel pistons, which increase resistance to corrosion, making them ideal for challenging conditions, such as on yachts.

Operating principle of an electric actuator

Electric actuators operate based on electromagnetism, converting electrical energy into mechanical movement. The key component is the electric motor, which generates rotary motion. This motion is then transmitted to a drive transmission mechanism, which converts it into linear or rotary motion, depending on the actuator’s design. This enables electric actuators to precisely control the movement of machines and devices, which is essential in many production processes.

Selecting electric actuators for automation

Choosing the right electric actuator depends on the requirements of a specific industrial application. The key parameters to consider include:

• Force: Determines how much force the actuator can generate.
• Speed: Varies depending on the application – some processes require faster operation, while others need precise, slower movements.
• Durability: The long-term use of an electric actuator depends on its design and working conditions. Regular maintenance and proper parameter selection help maximize durability and ensure optimal performance.

Installation and mounting of electric actuators

The installation of electric actuators requires precision and compliance with manufacturer guidelines. Compared to pneumatic systems, where selecting the right components impacts efficiency and reliability, electric actuators also require consideration of technical parameters, such as working pressure, airflow, operating speed, and temperature range. Additionally, ensuring proper working conditions minimizes the risk of failure.

Pay attention to working conditions

Electric actuators can be sensitive to extreme conditions, such as low temperatures, which may affect their performance. Unlike electric actuators, pneumatic actuators may perform better in such environments, making them more suitable for extreme conditions. In such cases, choosing materials resistant to external factors and performing regular maintenance can significantly extend the lifespan of the device.

Controlling electric actuators

Precise control of an electric actuator is essential for ensuring its efficiency. Modern control systems allow for accurate motion control, which is particularly important in processes requiring repeatability and high precision. Remote control and monitoring of actuator status optimize machine performance and prevent failures.

Comparison: electric vs. pneumatic actuators

Both electric and pneumatic actuators are commonly used in industrial applications, but they differ in characteristics and applications.

• Precision and control: Electric actuators provide higher precision and better motion control compared to pneumatic actuators. Thanks to advanced control systems, electric actuators can perform highly accurate movements, essential in high-precision applications.
• Operating costs: Electric actuators are more energy-efficient and require less maintenance than pneumatic actuators. Eliminating compressed air systems reduces operational costs and simplifies installation.
• Environmental resistance: Pneumatic actuators are more resistant to extreme conditions, such as high temperatures and humidity, making them better suited for harsh environments where electric actuators may be less efficient.
• Lifespan: Electric actuators typically have a longer service life than pneumatic actuators due to their robust design and lower maintenance requirements.

Maintenance and servicing of electric actuators

To ensure optimal performance and extend the lifespan of electric actuators, regular maintenance is necessary. Key maintenance steps include:

• Routine inspections: Regularly check the actuator’s condition, including the motor, gearbox, and mechanical components. Early detection and repair of faults can prevent severe failures.
• Cleaning: Keeping the actuator clean prevents the accumulation of dust and contaminants that can affect performance.
• Lubrication checks: In actuators that require lubrication, monitor oil levels and refill as needed. Proper lubrication is essential for smooth operation.
• Checking cables and connections: Regularly inspect electrical wiring and connections to prevent damage and ensure reliable operation.

In the event of a failure, immediately disconnect the actuator from the power supply and contact the manufacturer or an authorized service provider for professional assistance. Regular maintenance is crucial for ensuring long-term, reliable operation in industrial automation applications.

Advantages of electric actuators in industrial automation

Electric actuators offer numerous advantages compared to traditional pneumatic or hydraulic systems. Unlike pneumatic components such as compressors, valves, and actuators, electric actuators require less maintenance and offer higher efficiency.

• Precise control: Electric actuators provide high accuracy, which is especially important in applications requiring fine-tuned precision.
• Long lifespan: Due to their solid construction and minimal maintenance requirements, electric actuators last longer.
• Lower operational costs: The lack of compressed air or hydraulic oil requirements makes electric actuators more cost-effective compared to pneumatic or hydraulic systems.

Conclusion

Electric actuators are essential in modern industrial automation, offering unmatched precision, efficiency, and longevity. With proper selection, installation, and regular maintenance, electric actuators can ensure reliable and optimal performance in production processes. AMG Automatyka provides a wide range of electric actuators tailored to industrial needs, offering support at every stage of their operation.