Production Challenges Can Point to the Need for a High Force Electric Actuator

On paper, a manufacturing line can look efficient, but subtle motion flaws can gradually degrade efficiency. Not every cycle will deliver components to the same location. Heavy loads may be too slow. Operators may have to make frequent modifications to maintain equipment working appropriately. These problems may suggest that the existing motion system is no longer a good fit for the application. In some circumstances a high force electric actuator can give the controlled linear movement to increase the placement and performance of the machine.

The goal is to identify the real production problem before you choose new equipment. Strength is merely one factor. Speed, stroke, duty cycle, positioning requirements, load characteristics and system integration can affect actuator selection.

When Production Problems Point to a Motion Issue

Not every delay in production is an actuator. A machine may have difficulties with its controls, mechanical parts, sensors or the process itself. However, some of the patterns can indicate that the motion system is worth a deeper look.

Repeated Positioning Errors

Any component that ends up in a little changed position each cycle can cause quality concerns.

This is relevant to machinery carrying out assembly, pressing, transporting or inspection jobs. Small errors in placement might add up over a high volume production run. Operators may compensate by slowing the machine or by manual adjustments.

Heavy Loads Struggle During Movement

Some production equipment has to transfer high loads under regulated motion.

If a machine has difficulty in accelerating, or needs to stop and start again, it may be because the existing drive system does not give enough usable thrust for the application. Engineers should not assume that the solution to a problem is simply to select a larger actuator without looking at the actual load and motion profile.

A high force electric actuator would be suitable for an application that requires large linear force with regulated movement. The needed force shall be determined on the basis of the load, acceleration, friction, orientation and other operating parameters.

Choosing Force Without Sacrificing Control

More force does not always guarantee better results. The actuator shall be capable to full motion demand.

Start With the Actual Load

Engineers need to know what the actuator will move.

Calculations may include load weight, acceleration, friction, mounting position, stroke length and desired speed. Vertical applications could be something else to think about . The force demand is influenced by gravity .

Choosing equipment based on force rating alone could result in an oversized or mismatched system.

Consider Speed and Cycle Time

Of course, the quality of production equipment is generally measured by how fast it can cycle.

If a system has a high force but travels too gradually, it may not be able to overcome the production bottleneck. In contrast, increasing speed, without consideration for load and stopping needs, can have an impact on positioning and machine safety.

The ideal way to do it is a combination of force, and the right speed and cycle profile.

When Automation Exposes a Weak Point

Production issues often become easier to identify after a facility adds more automation. Faster machines can reveal limitations that were less noticeable when production volumes were lower.

Conveyor Systems Need Controlled Transfers

Material movement can be a bottleneck where products need to be lifted, pushed, deflected or positioned over and over.

A well-chosen actuator can control these movements with uniform timing. In conveyor system automation this may comprise transfer mechanisms, brakes, positioning devices and lifting operations. The actuator still needs to be adapted to the requirements of the unique machine regarding a load and cycle.

Energy Recovery Can Improve System Efficiency

Repeated acceleration and deceleration may influence energy usage in automated machinery.

Some systems implement regenerative energy systems to recuperate energy generated during deceleration. The recovered energy can be sent back to the electrical system or handled with the suitable drive architecture. Whether this strategy makes sense depends on the machine operating profile and equipment used.

Energy recovery must be considered as part of the whole system and not as an inevitable advantage of any electric actuator installation.

Safety Cannot Be Added as an Afterthought

Machinery applying high force has to control movement and stopping carefully.

A functional safety system can use safety-rated components, monitoring and defined stop functions to limit the risks associated with hazardous machine movement. The suitable design is a function of the dangers of the machine and the findings of a risk assessment .

Force, speed, stopping distance, access points and operational conditions should be considered in system design.

Drives Influence How Motion Behaves

Motor and drive can have a large impact on actuator performance. The choice of the actuator without reference to the rest of the motion system can lead to unwanted constraints.

An Industrial VFD Can Control Motor Behavior

An industrial VFD controls the frequency and speed provided to a suitable AC motor. It can enable controlled acceleration and deceleration and allow motor speed to be varied to the application.

VFDs are broadly utilised in industrial automation, although the suitable drive technology depends on motor, motion requirements and control architecture. In applications that need accurate servo positioning, a new technique to motion control may be needed.

FAQs

What Signs Suggest an Actuator May Be Undersized?

Signs that the current system needs to be assessed include repeated positioning problems, difficulty transferring the requisite load, uneven cycle performance, too much manual input or frequent motion-related defects. These symptoms may be caused by other things, thus it is vital to do a comprehensive assessment of the equipment.

Is a High-Force Actuator Suitable for Every Heavy-Duty Application?

No. Force is just one selection factor. Apart from the design considerations of torque and power, the engineers have to consider the speed, stroke, duty cycle, load characteristics, mounting arrangement, precision, climatic conditions and control needs.

Conclusion

Sometimes production problems show that the motion system of a machine does not correspond to the workload. If an application demands more linear force and regulated, repeatable motion, then a high force electric actuator can be a suitable choice. The best results are obtained by analysing the whole system, not only the force. When automating their conveyor systems, producers can also look at motion control, safety, energy management and drive technology in tandem to create equipment that works dependably as production needs change.