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You are here: Home / Linear Motion / Actuators / Motion systems application examples: Electric actuators for versatility in motion

Motion systems application examples: Electric actuators for versatility in motion

November 20, 2015 By Lisa Eitel Leave a Comment

Electric actuators range from syringe-sized units in medical applications to those that drive truck-sized industrial presses. These ubiquitous muscles of precision motion usually incorporate an electric motor and rotary-to-linear device for conversion of torque to linear force.

So let’s cover common motion applications for this component type.
03-PHD-robotic-application-slides
In this conveyor setup, SFP, SD and SE slides from PHD, Inc. route products off of a conveyor line, while optical sensing identifies routed pieces. Such setups quickly and effectively separate product for packaging and distribution.

No matter the application, electric actuators deliver precision and repeatability—indispensable for repeatedly moving loads to a given location or locations. In some cases, they’re also more controllable than fluid-power options, giving engineers a viable way to shape the speed, force and acceleration of machine-axis moves.

Shown here is an electric throttle actuator from Thomson Linear. With the help of controls, it goes on or near the throttle linkage to boost the efficiency of traditional diesel engines. It just needs an electrical cable or communications bus to the cab.
Shown here is an electric throttle actuator from Thomson Linear. With the help of controls, it goes on or near the throttle linkage to boost the efficiency of traditional diesel engines. It just needs an electrical cable or communications bus to the cab.

Another benefit for applications that must deliver different outputs over time is that many electric actuators are programmable, so can adapt to changing conditions. Exceptions abound, but applications with similar dynamics generally make use of similar actuators—those that pair motors with ballscrews; incorporate brushless dc motors; use leadscrews; come in a rod style; integrate belt-and-pulley setups; use motors paired with planetary roller screws; or are fully integrated actuators with built-in guides.

Once the domain of fluid-power components, even off-highway equipment is incorporating more electric actuators than ever ... mostly to automate adjustments and tracking once done manually or not at all.
Once the domain of fluid-power components, even off-highway equipment is incorporating more electric actuators than ever … mostly to automate adjustments and tracking once done manually or not at all.

Note that electric actuators that work closed-loop or with a micro-stepping motor can match force and speed output commands best using feedback to overcome most of the mechanical limitations of rotary-to-linear devices.

Some application tips: No matter the application, establish the design’s power draw. Determine if the machine needs continuous or intermittent power draw, as that will dictate actuator size and type. Remember that overly large electric actuators can be less responsive than properly sized units.

Shown here is a dual-band fluorescent microscope from Kessler Optics and Photonics Solutions. According to engineers at MICROMO (FAULHABER Group) actuators with a through-hole design can be useful in similar applications (to position optical components while beams shine through an aperture). The result is precise performance in a very compact system, and an aperture that lets cables run through the center to save space and reduce cable fatigue.
Shown here is a dual-band fluorescent microscope from Kessler Optics and Photonics Solutions. According to engineers at MICROMO (FAULHABER Group) actuators with a through-hole design can be useful in similar applications (to position optical components while beams shine through an aperture). The result is precise performance in a very compact system, and an aperture that lets cables run through the center to save space and reduce cable fatigue.

On the other hand, appropriate safety factors ensure that electric actuators run coolly. Plus, lighter loads on the mechanical components can extend life. Halving load on a leadscrew can extend its life eightfold, for example.

Shown here is one example of how manufacturers often build actuators to specific requirements—in this case, an actuator on a spot-welding robot. GSWA ServoWeld actuators from Tolomatic are one of myriad job-specific offerings from the company. The actuators are lightweight and have an enclosed anti-rotate assembly to offer an alternative to pneumatic welding actuators. When used in P (pinch), C, X, or Euro guns, they speed spot-weld cycles and boost quality, making more repeatable welds than those with pneumatic actuators. A hollow-core servomotor pairs with either a ball or roller screw to output efficient, repeatable high force, lasting more than 10 million cycles and eliminating the need for couplings, adapters, belts and gears.
Shown here is one example of how manufacturers often build actuators to specific requirements—in this case, an actuator on a spot-welding robot. GSWA ServoWeld actuators from Tolomatic are one of myriad job-specific offerings from the company. The actuators are lightweight and have an enclosed anti-rotate assembly to offer an alternative to pneumatic welding actuators. When used in P (pinch), C, X, or Euro guns, they speed spot-weld cycles and boost quality, making more repeatable welds than those with pneumatic actuators. A hollow-core servomotor pairs with either a ball or roller screw to output efficient, repeatable high force, lasting more than 10 million cycles and eliminating the need for couplings, adapters, belts and gears.

Also account for the application environment and any dirt, chemicals and liquids that will contact the actuator. O-rings and seals must be made of materials that withstand the application’s suite of contaminants. Finally, ensure that the electric actuator can handle the application’s side, radial and axial loads.

Technology applications:
Matching actuators to design demands

Electric actuators for automation applications must deliver set levels of speed and force requirements. Here, better feedback and controls can increase responsiveness to overcome any mechanical limitations while boosting output-motion accuracy. OEMs and end users can pick from a vast array of actuators to get the right level of accuracy—for everything from lumber-processing machines to those medical applications that need accuracy to a few micrometers. Electric-motor actuators that use belts and acme screws for rotary-to-linear conversion of motion abound. That said, the majority of general motion applications (including positioning tables, workpiece-pivoting stations, robotic end effectors and machining axes) make use of actuators that integrate ballscrews. With precision of down to micrometers, these satisfy designs that need thrust to thousands of pounds-force or linear positioning speeds to several feet per second.

Elsewhere, on injection-molding applications, packaging machines, machine presses and other setups that need high thrust, actuators that pair the electric motor with a roller screw (sporting a nut loaded with roller bearings that work like planetary gears around the screw) is a newer and increasingly common option. Typical stroke is 2 m with acceleration to a few gs.

Common actuator types

Benefits and potential limitations

Typical uses

Actuators pairing motors
with ballscrews

• High axial output force for given torque input (mechanical advantage)

• Speed and stroke limits

Industrial, transportation, aerospace and defense

Actuators with brushless dc motors

• None of the wear of brush motors; long life

• More costly initially and potentially complicated drive

General-purpose applications; axes run at high speed; appliances; factory automation

Actuators with leadscrews
(or Acme screws)

• Simplicity and (in some versions) integration of guide function

• Variable life due to sliding wear

Ruggedized equipment; lower-cost consumer products; machine-tool transport

Rod-style actuators

• High force output (especially screw-driven types); hygienic

• Seals can increase cost

Medical applications needing sealed motion components; sorting and food processing

Actuators with belt-and-pulley setups

• Extremely high speeds and long strokes; short design lead times

• Limited precision without guides

Horizontal and vertical designs; small conveying to large SCARA transport

Fully integrated actuators
(with built-in guides)

• Simple installation

• Less design freedom

Consumer products to medium-volume industrial machines

Linear motors

• Fast and accurate

• More costly than alternatives

Ultra-high-precision applications in semiconductor, medical and more

Motor paired with planetary roller screw

• Fast, accurate and precise

• More demanding installation requirements

Precision applications in aerospace and semiconductor

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Filed Under: Actuators, Motion Casebook Tagged With: Bishop-Wisecarver (BWC), phd, Tolomatic

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