When Do You Actually Need a High Force Electric Actuator?

Not every automated machine requires the most demanding pushing or lifting strength. However, there are applications that require controlled motion with heavy loads, accurate positioning and repeatable performance over many cycles of operation. In such cases, a high force electric actuator can be a realistic solution for translating electrical energy into controlled linear motion.

It relies on more than the demand of force. The suitability of this sort of actuator should be considered in terms of load size, travel distance, speed, positioning accuracy, duty cycle, available space and control needs.

Heavy Loads Require More Than Basic Linear Motion

Some machines can do simple work with rather light loads. Others need to push, press, lift, clamp or place parts that need substantially more force.

If you can not get lighter actuators to safely and reliably carry that load you may need a high force system.

Repeated Force Demands Can Affect Equipment Selection

An actuator may do well in infrequent operation, but may not do well when asked to repeat the same movement throughout the course of an entire manufacturing shift.

A high force electric actuator can be considered when the application has to develop large force over several cycles with controlled movement and positioning.

Engineers also need to consider the duty cycle because continuous or frequent operation might impact heat generation, mechanical wear and the life of the equipment.

Load Direction Also Matters

The actuator selection may depend on the direction of movement. Horizontal pushing or pulling may have distinct considerations than vertical lifting applications.

In determining real force requirements all external forces, friction, acceleration and weight of connected components should be incorporated.

Precision Matters Along With Force

High force does not imply that placement accuracy is irrelevant. Both are needed in many industrial applications.

Manufacturing equipment may need to transfer a heavy part into an exact place before another activity begins. A slight placement error might damage product quality or disrupt the next phase of manufacturing.

Programmable Movement Supports Complex Processes

The electric motion systems can be paired with controllers to control position, speed and movement sequences.

This is useful when a machine needs to conduct distinct motions at different stages in a production process. Programmable controls can also eliminate the need for significant mechanical changes as operating requirements change.

Consistency Can Improve Production Results

Repetitive manufacturing utilizes technology that can make predictable movements.

For applications where the same regulated force and motion is required repeatedly without manual modification between cycles, a high force electric actuator may be appropriate.

Material Handling Systems Can Create High Force Requirements

As products move through a plant they may need to be lifted, transferred, diverted or positioned. This may require large loads.

varying material handling applications have varying requirements depending on product weight, manufacturing speed and system design.

Coordinated Equipment Improves Material Flow

In larger operations, conveyor system automation to link different areas of the production or distribution process.

Combined with other equipment, actuators can be utilized to regulate transfer mechanisms, gates, lifting systems and positioning devices. The specific layout will depend on the flow of materials through the facility.

Sudden Load Changes Need Consideration

Some applications deal with goods of different weights. An actuator intended for a constant load may not react the same way when heavier goods are introduced into the system.

Engineers should pick equipment based on maximum operating circumstances rather than normal loads.

Energy Performance May Influence the Decision

More manufacturers are looking at how equipment utilizes energy in normal operation.

Electric motion systems work based on their program movement needs. For some applications, regenerative energy systems that capture energy generated during deceleration or other operating circumstances may also be considered, depending on the system design.

The possible benefits are a function of the equipment configuration and the application requirements.

System Sizing Can Affect Efficiency

Oversizing of equipment leads to excessive costs whereas undersizing of equipment results in poor performance or premature deterioration.

Accurate load calculations help engineers pick equipment that will meet actual operational requirements.

Drives Help Control Motor Performance

Motor control can impact acceleration, speed and deceleration.

In some instances an industrial VFD may be utilized to control the motor operation and also provide a smoother running of the equipment as the process needs change.

Safety Requirements Should Be Considered Early

Any automated system, generating significant force, demands rigorous safety consideration.

The risk assessment should take into account normal operation, maintenance, unexpected behavior of equipment and any interaction between people and machinery.

A functional safety system can form part of a broader machine safety approach by monitoring conditions and responding when predefined safety limits are reached.

Safety Is More Than an Emergency Stop

Emergency stops are crucial, but guards, sensors, interlocks, safe operating practices, and appropriately built control systems can also be part of machine safety.

How to do it correctly relies on the particular equipment and its risk assessment.

FAQs

How do you determine the force required for an electric actuator?

The calculation will include load weight, direction of travel, friction, acceleration, mechanical resistance and any other forces caused by the application.

Can electric actuators be used for pressing applications?

Yes. Electric actuators can be employed in pressing and assembling applications, if the chosen system offers the necessary force, motion control and positioning capabilities.

Does a high-force actuator require a complex control system?

Not always. The level of control necessary depends on the application. Simple movements might need basic controls . Complex automation may require programmable motion and coordinated equipment.

Conclusion

The first step in choosing the proper motion technology is to understand the true requirements of the application. The selection of equipment should take into account force requirements, accuracy of movement, operating frequency, fluctuation of load, energy usage and safety. A high force electric actuator may be a good candidate for heavy load applications that need controlled and repeatable motion. With careful preparation of the system the end result can be a solution that performs reliably and does not add additional complexity.