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Key factors in selecting electric actuators for high-force applications
Choosing the right electric actuator for high-force applications is critical for ensuring system reliability, efficiency, and safety. At the outset, it is essential to consider core factors such as load capacity, durability, drive mechanism, positioning accuracy, and resistance to operating conditions. From the very beginning, it’s important to focus not only on technical parameters, but also on how the actuator integrates into the overall system architecture.
The first and most important step is to determine the actual forces and torques the electric actuator must transmit in your application. High loads require precise calculations, as underestimating requirements can lead to mechanical failure or total system breakdown.
Both static forces (holding position) and dynamic forces (e.g. those arising during acceleration or deceleration) must be considered. If the application involves lifting, moving, or holding heavy loads, it is crucial to calculate these forces in newtons or newton-meters. A safety margin—typically between 20% and 50%—should also be factored in.
Force direction matters as well—inline actuators behave differently from actuators operating at an angle. Knowing these parameters helps narrow down the selection to actuator models capable of meeting your force requirements.
Linear speed and duty cycle are critical factors that influence actuator performance and service life. In applications involving frequent starts and stops, dynamic performance becomes a key consideration.
Speed affects system response time, which is vital in industrial automation, where milliseconds count. Excessive speed without adequate stability can result in vibration or overload.
Duty cycle defines how frequently the actuator operates throughout the day—this directly impacts lifespan and maintenance intervals. For continuous operation, components with high-duty cycle ratings are essential.
The load capacity of an electric actuator defines the maximum force it can handle without the risk of overload. In high-force applications, actuator selection must account not just for load weight, but also for acceleration, friction, and inertia.
High-load actuators often feature robust constructions using guide shafts, ball screws or trapezoidal screws, and integrated bearings that increase mechanical strength. If your application involves moving heavy platforms, conveyors, or process cylinders, the minimum rated load should be at least 1.5 times the expected working load.
Keep in mind that load capacity applies to both static and transient forces—such as impact or shock loads encountered during operation.
Actuator stroke—defined as the distance the rod can travel—directly determines the motion range of the mechanism. In high-force technical applications, not only stroke length but also stop accuracy and motion repeatability are crucial.
Precision is vital in machining, packaging, or assembly processes, where even minor deviations can result in significant loss. High-end actuators can offer repeatability within ±0.01 mm—important if your process requires tightly controlled movement.
Also check if the actuator offers configurable stroke settings—limit switches, encoders, and programmable options can significantly increase system flexibility.
For high-force applications, component lifespan—measured in operating hours or motion cycles—is of utmost importance. Frequent use requires actuators designed for longevity: reinforced components, thermal protection, and vibration resistance.
The duty cycle is the ratio of run time to rest time—for example, a 50% duty cycle means the actuator can operate for 5 minutes, then must cool down for 5 minutes. Exceeding this ratio drastically shortens actuator life.
Choose actuators backed by long warranties and OEM service support with access to spare parts.
Electric actuators typically use either ball screws or trapezoidal screws to convert rotary motion to linear thrust. Both have benefits—but performance and durability differ, especially under heavy load.
Ball screws offer higher efficiency (up to 90%) and greater positioning accuracy due to rolling elements. They’re ideal for high-duty-cycle applications with tight tolerance requirements. Downsides include higher cost and sensitivity to contamination.
Trapezoidal screws operate via sliding friction, offering lower efficiency (30–50%) but better resistance to dust and debris. They’re well-suited for slower, high-force applications where torque matters more than speed.
Choose based on priorities: speed and precision – ball screw; simplicity and force – trapezoidal screw.
The motor is the heart of the actuator. In high-load scenarios, the choice is usually between servo and stepper motors, depending on control, accuracy, and dynamic requirements.
Stepper motors offer simple control, cost-efficiency, and precise incremental motion. They’re great for position-based tasks with moderate dynamics. However, torque decreases with speed, which limits use in heavier systems.
Servo motors provide higher torque, better efficiency, and real-time control capabilities. Integrated with encoders, they adjust motion based on load changes. This makes them ideal where fast acceleration, deceleration, and closed-loop control are critical.
The choice of housing and structural materials impacts fatigue resistance, environmental suitability, and actuator weight. In metallurgy, assembly, and logistics, high forces require sturdy construction.
Stainless steel is best for high-humidity, chemical exposure, or dusty environments. It offers excellent corrosion resistance and outdoor durability.
Aluminum provides good strength with lower weight, making it suitable for mobile applications. Engineering plastics and composites can be used in non-load-bearing parts to improve insulation and weight.
Always choose materials based on operational conditions: temperature, moisture, oil contact, and airborne particles.
High-force tasks are often performed in harsh conditions—such as steel plants, cement factories, or marine environments. Anti-corrosion protection ensures long-term reliability.
Ingress protection (IP) ratings like IP65 or IP67 indicate dust and water resistance. For outdoor use, additional treatments like galvanizing, anodizing, or powder coating are recommended.
Seals matter too—in tough conditions, use multi-lip or self-lubricating seals. Consider adding heaters or ventilation systems in case of extreme temperature fluctuations.
Reliable and responsive actuator control depends on communication protocol compatibility. The best protocol depends on application type and system integration needs.
• CANopen – ideal for distributed control systems with high noise immunity
• EtherCAT – ultra-fast, suited for CNC and robotics
• PROFINET – common in industrial automation
Ensure your interface is compatible with your PLC, HMI, and diagnostic tools.
Safety is critical in high-force applications. The actuator should support emergency stops, limit switches, and integration with safety devices like light curtains or RFID systems.
Predictive diagnostics is increasingly used—integrated sensors monitor temperature, force, and humidity to detect issues before failure occurs.
This supports scheduled maintenance and reduces unplanned downtime, directly affecting operational costs.
Proper installation ensures actuator longevity. All mounting surfaces must be level, and fasteners torqued per manufacturer recommendations.
Ensure:
• Use of appropriate dampers and shock absorbers
• Correct limit switch positioning
• Independent overload protection systems
Before commissioning, run a no-load test cycle to confirm smooth, backlash-free motion.
Routine inspections detect wear signs early—before major failures occur.
Recommendations:
• Weekly visual inspections
• Monthly checks of mechanical backlash and noise levels
• Biannual maintenance with torque and temperature logging
Modern sensors and alarms significantly boost system reliability and safety.
Conclusion
Selecting the right actuator for high-force applications requires careful analysis of technical and environmental factors. Load capacity, durability, drive type, control quality, and total cost of ownership are all critical. Materials, protective features, and proper installation also play a key role.
Making informed decisions during the planning phase helps eliminate potential failure points and enhances overall system performance.
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