Optimization of control in electric actuators – how does it work?

Electric actuators are one of the key components of industrial automation. They are responsible for precise motion control in machines and devices, and their correct operation directly affects the efficiency, safety, and energy savings of processes. Optimization of control in electric actuators not only increases efficiency but also significantly reduces the risk of failures and maintenance costs.

Methods of control optimization

Pid tuning – how to adjust the parameters?

The PID controller (proportional-integral-derivative) is the most commonly used control method in actuator systems. To achieve optimal performance, three key parameters must be carefully tuned: Kp (proportional gain), Ki (integral gain), and Kd (derivative gain). Their selection directly impacts the stability, response speed, and damping of oscillations in the system. Calibration can be carried out manually or with the use of automatic tuning algorithms. In practice, it is recommended to start with adjusting Kp, then add Ki to reduce steady-state error, and finally adjust Kd to smooth the dynamic response.

Advanced adaptive and predictive algorithms

Modern systems use adaptive and predictive control algorithms (MPC – Model Predictive Control), which dynamically change parameters depending on current conditions. Adaptive control allows adjustment to variable loads or mechanical wear, ensuring consistent performance. MPC, on the other hand, predicts future system states and makes optimal decisions in advance. This technology is especially valuable in applications requiring high precision and reliability.

Use of sensors and feedback

Position, speed, and torque sensors play a key role in feedback systems. Thanks to them, monitoring and correction of actuator operation in real time is possible. Closed-loop feedback ensures greater precision and eliminates errors caused by external disturbances. Modern installations also employ intelligent diagnostic systems that analyze sensor data and detect early signs of failures.

Practical steps for implementing optimization

Needs analysis and selection of appropriate tools

The implementation of control optimization should begin with a thorough analysis of production processes, business objectives, and existing technical constraints. Key questions include: what do we expect from the actuator, which parameters are critical, how often does the load change? Based on this, control algorithms, sensor types, and communication technologies are selected. Computer simulations or pilot tests may be necessary before full integration in the production environment.

Integration with PLC and SCADA systems

Integration with supervisory systems such as PLC (Programmable Logic Controller) and SCADA (Supervisory Control And Data Acquisition) allows full automation and remote control of processes. PLC enables local logic control of actuator operation, while SCADA collects and analyzes data at the management level. Proper configuration of communication protocols (e.g., Modbus, Profinet, Ethernet/IP) ensures reliable cooperation of all components. It is also important to take care of transmission security and redundancy of critical channels.

Testing and validation of parameters

After installing and configuring all system components, functional tests and parameter validation are carried out. The goal is to verify that the electric actuator operates according to expectations: reaches designated positions, responds within the required time, and maintains stability. Tests should be performed under various load conditions, and any deviations corrected by tuning controllers or modifying the control code. Regular verification ensures the system remains in optimal condition for a long time.

Benefits of optimization

Increased efficiency and reduced energy costs

Well-optimized actuator control brings tangible economic benefits. By maintaining higher accuracy, machines operate faster, without downtime, and with reduced energy consumption. Energy savings of 10–30% are possible thanks to the elimination of unnecessary movements, slowdowns, or setting errors. This translates not only into lower bills but also increased production line throughput.

Improved machine safety and reliability

Continuous monitoring of parameters and adaptive response to anomalies enables quick detection of malfunctions, prevention of overloads, and minimization of mechanical damage risks. Good control also supports compliance with machine safety standards (e.g., ISO 13849), enhancing protection for operators and equipment. Combined with intelligent diagnostics and remote monitoring, response times to failures are also improved.

Extended actuator lifespan

Reducing mechanical stress and the number of work cycles, while maintaining full functionality, significantly extends actuator lifespan. Fewer sudden movements and better cooperation with drives result in slower wear of components. This reduces the frequency of maintenance, and the actuator continues stable operation for years.

Optimized actuator control is an investment that pays off quickly – in the form of better quality, lower costs, and peace of mind for operators.