This is especially true with electric rod-style actuators due to their higher initial cost, more complex design and more predictable performance compared to fluid power cylinders, both pneumatic and hydraulic.

Figure 1: Motor, screw and bearing selection must match the anticipated load capacity of the actuator for best performance and durability.

Additional engineering and analysis at the front end of an electric actuator application will reduce overall costs and result in automation systems with higher reliability, better performance, lower energy expenditures and less maintenance. In the hurry to get factory automation applications up and running, there is always the impulse to make educated guesses or take shortcuts.

Following are the top ten tips for optimal performance, reliability and efficiency of your electric rod-style actuator application.

Tip Number 1: Calculate loads precisely  

The ability of an electric rod-style actuator to perform its intended task with accuracy, speed and durability is dependent on matching the electric motor, the lead screw and the bearings to the anticipated loads. By knowing the precise static and dynamic loads of the application and matching them to the peak and continuous load capabilities of the actuator, the application will be both cost-effective and reliable.  See Figure 1.

Tip Number 2: Calculate for electric, not fluid power (pneumatic or hydraulic)  

Oversizing actuators is a bad habit left over from fluid power applications where oversizing was considered inexpensive insurance against not having enough power. With fluid power cylinders, the additional cost of a slightly larger actuator than necessary was minor compared to the extra engineering time that might be involved in sizing it correctly. It was common for engineers to build in a 2:1 safety factor on fluid power applications for a variety of reasons.

These included erring on the conservative side to compensate for imprecise knowledge of the loads, fluctuations in available air pressure and oversizing in anticipation of higher loads in the future due to production growth or application changes. Electric actuators can cost significantly more up front, so oversizing is a more costly mistake.  Avoid oversizing by properly matching the actuator to the application. Sizing programs, graphs and formulas available from actuator manufacturers make this task easier and more accurate than in the past. See Figure 2.


Figure 2: Tolomatic offers both Application Data Worksheets and Windows-based sizing and selection software to simplify the sizing and selection process.

Tip Number 3: Factor in duty cycle 

Duty cycle is defined as a ratio of operating time to resting time of an electric actuator expressed as a percentage. An actuator that is moving for two seconds and stopped for two seconds has a duty cycle of 50 percent. Underestimating the impact of duty cycle on an actuator can lead to overheating, faster wear and premature component failure. 



Overestimating the impact of duty cycle can lead to higher initial costs due to oversizing. Typical conservative duty-cycle estimates often stem from an incomplete understanding of the application.

Tip Number 4: Know required force and velocity

When considered together, force and velocity requirements dictate the capabilities of motors, screws and nuts in electric rod-style actuators. A common error is specifying a stepper motor to save money when a servomotor may be more appropriate for velocity and force requirements.

As the speed of a stepper motor increases, its available force drops off precipitously, whereas servomotors are able to maintain their force even as speed increases. Similarly, force and velocity requirements will dictate the type and pitch of the lead screw – whether it is an Acme screw with either composite or bronze nut, or a ball screw or roller screw. By knowing the precise speed and velocity requirements of the application, it is possible to specify an actuator with the proper components needed for high performance and long service life.  See Figure 3. 



Figure 3: Use the screw charts supplied by the actuator manufacturer to determine if your thrust and speed requirements are compatible with actuator/screw capacities.

Tip Number 5: Employ proper guides and avoid side loading 

A rod-style actuator is vulnerable to damage and wear if the extended rod is subjected to even moderate side loads. Side loads on the rod usually occur when the actuator is out of alignment with the main load, causing severe wear to the front bearing and damage to the lead nut.

The mounting of the actuator can also be a factor. For example, an actuator rod will have a tendency to run out of alignment at maximum stroke when it is mounted with a clevis type rod end, creating significant side loads on the rod and support bearing. To avoid side loading, be sure the actuator rod has an appropriate mounting and is either guided or precisely aligned with the load.

Tip Number 6: Set critical speed limits

Higher operating speeds can often improve manufacturing throughput, but in a rod-style actuator, lead screw critical speed becomes an upper limit. Critical speed refers to the rotational speed that excites the screw’s natural frequency. When a screw reaches critical speed it begins to oscillate or “whip.”

The critical speed limit is dependent on the screw length and diameter. As the stroke length increases, the distance between the support bearings increases, causing screw oscillation over a certain speed. This oscillation prematurely wears the support bearings and can result in vibration, noise and even catastrophic failure.  See Figure 4.


Figure 4: When the stroke of a rod-style actuator increases so does the distance from the actuator’s support bearing. In some cases, if the distance becomes greater than the capacity the screw and bearing can handle, oscillation of the screw occurs, placing stress on the bearings.

Tip Number 7: Match peak thrust to actuator

The peak thrust needed for the application cannot exceed the peak thrust that can be delivered by the actuator. First determine what the peak thrust requirement is for the application and then compare that to the thrust curve for the selected actuator. Thrust curves from actuator manufacturers show a combined peak and continuous thrust capability.

For most of the duty cycle, the thrust stays under the continuous thrust curve. Make sure that the actuator’s peak and continuous thrust capabilities are properly matched to the motor; some motors can provide more peak thrust than the actuator can withstand, causing stresses that will lead to premature failure. It is equally important to perform necessary column strength calculations and verify that the actuator is capable of providing the required peak thrust without screw or rod buckling.  See Figure 5



Figure 5: Be sure to use the manufacturer’s tables or charts to determine the maximum thrust capacity of the actuator and select the actuator that best fits the application

Tip Number 8: Factor in environment  

The environment in which the actuator will be operating can have a profound effect on performance, durability and maintenance. High temperatures can affect seals, lubrication, bearings and motor life. Extremely low temperatures can also affect performance, lubrication and wear.

Contamination with oil, water or abrasive grit can destroy seals unless the actuator has an appropriate IP rating. Since IP-ratings only address static conditions, dynamic conditions (vibration, heat, cold, movement) also have to be considered. 

Tip Number 9: Total envelope matters 

It is important to consider the overall actuator “envelope” – the length and width of the actuator and motor when the rod is fully extended. Failure to consider the total envelope may limit the size of motor that can be used or require an alteration in the layout of the application.

Be aware that the overall stroke length and actual working stroke length of an actuator will be different due to the “dead length” needed to accommodate internal features such as lead nut, bumpers and limiters. See Figure 6.



Figure 6.

Tip Number 10: Drive system is more than a footprint  

The actuator may be specified with an inline or reverse-parallel (RP) motor mount/drive system. While a RP system offers a more compact envelope, the RP is simply not as efficient due to the addition of belts or gears.

RP motor mounts do offer gear/belt ratios for a mechanical advantage and inertia matching, plus an additional mechanical mounting option of a rear clevis. Inline motor mounting offers the most efficient drive system and the highest dynamic performance. In some cases it is better to alter the application to make room for an inline motor drive than to specify a reverse-parallel drive where its performance characteristics may not be the best match. See Figure 7.



Figure 7: This illustration shows the space-saving feature of the reverse-parallel motor mounting option with a rear clevis as opposed to an inline configuration. Be sure to select the configuration that best suits the required performance.

Conclusion

Electric rod-style actuators offer enhanced performance, control and efficiency over their fluid power (pneumatic and hydraulic) counterparts. However, because of the higher initial cost of electric actuators and their unique characteristics vs. a fluid power cylinder, it is essential to fully understand the application requirements.

More productive and reliable automation systems will result from a careful determination and analysis of the loads, forces, application footprint and environment.  

About the Author:
Aaron Dietrich is product manager for Tolomatic’s electric product line. He has an extensive background in the motion control industry and has several years of experience working specifically in the drive and controls area as a design and application sales engineer. Aaron has a B.S. in electrical engineering from the University of North Dakota.  


About Tolomatic
For more than 50 years, Tolomatic has been a leading supplier of electric linear actuators, pneumatic actuators and power transmission products for factory automation. Its extensive product line also includes servo-driven high-thrust actuators, servo- and stepper motors, stepper drives, and configured linear-motion systems. Tolomatic’s electric linear and pneumatic actuators are used in a variety of industries, including the packaging, material handling, medical, food processing, automotive, semiconductor and general automation industries. For more information about the new SmartActuator ICR Basic and Plus, contact Tolomatic, 3800 County Road 116, Hamel, MN. Phone: 763-478-8000 or 1-800-328-2174.
www.tolomatic.com